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Engine - Automatic Transaxle

WARNING: This page is about a different car, the 2007 Mercury Mariner and 2007 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
Special Tools

Illustration Tool Name Tool Number
GF0000536
 Heavy Duty Floor Crane 014-00071 or equivalent
GF0000267
 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
GF0017081
 Powertrain Lift 014-00765
GF0024108
 Universal Adapter Brackets 014-0001
Lifting Bracket Set, Engine 303-D095 (D94L-6001-A) or equivalent
Material

Item Specification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil
XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalent		 WSS-M2C930-A
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury.

All vehicles 

  1. Using the engine crane and spreader bar, position the engine and transaxle together. Install the 6 transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
  2. Install new torque converter nuts.
    • Tighten to 35 Nm (26 lb-ft).
    3. Fig 1: Locating Torque Converter Nut
    G03897896Courtesy of FORD MOTOR CO.
  3. Install the starter motor isolator.
    4. Fig 2: Identifying Starter Motor Isolator
    G03897895Courtesy of FORD MOTOR CO.
  4. Using the engine crane and spreader bar, position the engine and transaxle onto the lift table.
  5. Using the special tools, secure the engine to the lift table.
    6. Fig 3: Securing Engine To Lift Table Using Special Tool (014-0001, 014-00765)
    G03897890Courtesy of FORD MOTOR CO.
  6. Raise the engine and transaxle into the vehicle.
  7. Install the bolt in the LH transaxle mount.
    • Tighten to 103 Nm (76 lb-ft).
    8. Fig 4: Locating Transaxle Mount Bolt
    G03897894Courtesy of FORD MOTOR CO.
  8. Install the bolt in the rear transaxle mount.
    • Tighten to 115 Nm (85 lb-ft).
    9. Fig 5: Transaxle Rear Mount Bolt
    GF0024141Courtesy of FORD MOTOR CO.
  9. Install the engine mount bracket and nuts.
    • Tighten to 115 Nm (85 lb-ft).
    10. Fig 6: Engine Mount Bracket & Nuts
    GF0024140Courtesy of FORD MOTOR CO.
  10. Install the engine mount bracket bolt.
    • Tighten to 115 Nm (85 lb-ft).
    11. Fig 7: Engine Mount Bracket Bolt
    GF0024139Courtesy of FORD MOTOR CO.
  11. Install the 2 transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
    12. Fig 8: Locating Engine-To-Bellhousing Bolts
    GF0024138Courtesy of FORD MOTOR CO.
  12. Install the 2 transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
    13. Fig 9: Locating Lower Bellhousing Bolts
    GF0024137Courtesy of FORD MOTOR CO.
  13. Install the engine support crossmember and new nut.
    • Tighten to 175 Nm (129 lb-ft).
    14. Fig 10: Identifying Cross Brace And Rear Nut
    G03897887Courtesy of FORD MOTOR CO.
  14. Install the 2 bolts for the engine support crossmember and the front roll restrictor bolt.
    • Tighten the engine support crossmember bolts to 90 Nm (66 lb-ft).
    • Tighten the front roll restrictor bolt to 115 Nm (85 lb-ft).
    15. Fig 11: Identifying Front Roll Restrictor Bolt & Bolts For Engine Support Crossmember
    G04619986Courtesy of FORD MOTOR CO.
    NOTE: The bolt under the power steering pressure tube will remain with the power steering pump.
  15. Position the power steering pump and install the bolts.
    • Tighten to 25 Nm (18 lb-ft).
    16. Fig 12: Identifying Power Steering Pump Bolts
    G03897742Courtesy of FORD MOTOR CO.
  16. Connect the power steering pressure (PSP) sensor electrical connector.
    17. Fig 13: Power Steering Pressure (PSP) Sensor Electrical Connector
    GF0024136Courtesy of FORD MOTOR CO.
  17. Install the A/C compressor and connect the A/C compressor electrical connector.
    • Tighten the bolts to 25 Nm (18 lb-ft).
    18. Fig 14: A/C Compressor Electrical Connector & Bolts
    GF0024135Courtesy of FORD MOTOR CO.
  18. Connect the lower radiator hose to the radiator.
    19. Fig 15: Locating Lower Radiator Hose
    G03897882Courtesy of FORD MOTOR CO.
  19. Install the 2 power steering pump bolts.
    • Tighten to 25 Nm (18 lb-ft).
    20. Fig 16: Locating Power Steering Pump Bolts
    G03897741Courtesy of FORD MOTOR CO.
  20. Install the ground wire and bolt.
    • Tighten to 10 Nm (89 lb-in).
    21. Fig 17: Locating Ground Wire & Bolt
    G03897880Courtesy of FORD MOTOR CO.
  21. Connect the powertrain control module (PCM) electrical connectors. Position the harness and install the nut.
    • Tighten to 6 Nm (53 lb-in).
    22. Fig 18: Locating Powertrain Control Module (PCM) Electrical Connectors
    G03897879Courtesy of FORD MOTOR CO.
  22. Attach the electrical connector retainers.
    23. Fig 19: Electrical Connector Retainers
    GF0024134Courtesy of FORD MOTOR CO.
  23. Connect the fuel supply tube.
    24. Fig 20: Locating Fuel Tube Quick Connect Coupling
    GF0024133Courtesy of FORD MOTOR CO.
  24. Connect the vacuum reservoir tube.
    25. Fig 21: Vacuum Reservoir Tube
    GF0024132Courtesy of FORD MOTOR CO.
  25. Connect the fuel vapor return tube and retainer.
    26. Fig 22: Fuel Vapor Return Tube
    GF0024131Courtesy of FORD MOTOR CO.
  26. Connect the vacuum supply tube.
    27. Fig 23: Vacuum Supply Tube
    GF0024130Courtesy of FORD MOTOR CO.
  27. Install the power steering tube, bracket and nut.
    • Tighten to 6 Nm (53 lb-in).
    28. Fig 24: Power Steering Tube Bracket & Nut
    GF0024129Courtesy of FORD MOTOR CO.
  28. Position the accelerator control cable and bracket and install the nut.
    • Tighten to 5 Nm (44 lb-in).
    29. Fig 25: Accelerator Control Cable Bracket & Nut
    GF0024127Courtesy of FORD MOTOR CO.
  29. Install the accelerator control cable and bracket and nut.
    • Tighten to 5 Nm (44 lb-in).
    30. Fig 26: Accelerator Control Cable Bracket & Nut
    GF0024128Courtesy of FORD MOTOR CO.
  30. Install the accelerator cable and speed control cable (if equipped).
    1. Connect the accelerator and speed control cable (if equipped) to the throttle body.
    2. Install the accelerator cable bracket and bolts.
      • Tighten to 10 Nm (89 lb-in).
    31. Fig 27: Accelerator Cable, Speed Control Cable & Bracket Bolts
    GF0024126Courtesy of FORD MOTOR CO.
  31. Install the accelerator cable snow shield and retainers.
    • Tighten to 10 Nm (89 lb-in).
    32. Fig 28: Accelerator Cable Snow Shield Retainers
    GF0024125Courtesy of FORD MOTOR CO.
  32. Connect the heater hoses to the heater core.
    33. Fig 29: Locating Heater Hoses
    G03897868Courtesy of FORD MOTOR CO.
  33. Attach the heater hose support strap to the stud.
    34. Fig 30: Heater Hose Support Strap & Stud
    GF0024124Courtesy of FORD MOTOR CO.
  34. Position the coolant vent hose and install the coolant vent hose brackets and nuts.
    • Tighten to 6 Nm (53 lb-in).
    35. Fig 31: Coolant Vent Hose Brackets
    GF0024123Courtesy of FORD MOTOR CO.
  35. Connect the upper radiator and coolant vent hoses.
    36. Fig 32: Upper Radiator Hose & Coolant Vent Hose
    GF0024122Courtesy of FORD MOTOR CO.
  36. If equipped, route the block heater wiring harness and attach all retainers. Connect the block heater electrical connector.
    37. Fig 33: Block Heater Electrical Connector
    GF0024121Courtesy of FORD MOTOR CO.
  37. Attach the transaxle control harness to the retaining clip.
    38. Fig 34: Transaxle Control Harness & Retaining Clip
    GF0024120Courtesy of FORD MOTOR CO.
  38. Install the output shaft speed (OSS) sensor and bolt.
    • Tighten to 13 Nm (10 lb-ft).
    39. Fig 35: Locating OSS Sensor Bolt
    G03897862Courtesy of FORD MOTOR CO.
  39. Install the fluid cooler tube.
    1. Connect the OSS sensor.
    2. Connect the turbine shaft speed (TSS) sensor (white connector).
    3. Position the bracket and install the bolt.
      • Tighten 13 Nm (10 lb-ft).
    4. Position the fluid cooler tube.
      • Tighten to 23 Nm (17 lb-ft).
    40. Fig 36: Fluid Cooler Tube, Electrical Connectors & Bracket
    GF0024119Courtesy of FORD MOTOR CO.
  40. Connect the rear transmission fluid cooler tube.
    41. Fig 37: Rear Cooler Tube At Transaxle Case
    GF0024118Courtesy of FORD MOTOR CO.
  41. Connect the front transmission fluid cooler tube.
    • Tighten to 23 Nm (17 lb-ft).
    42. Fig 38: Locating Transmission Fluid Cooler Tube
    G03897859Courtesy of FORD MOTOR CO.
  42. Attach the transaxle control harness to the brackets.
    43. Fig 39: Transaxle Control Harness Bracket
    GF0024117Courtesy of FORD MOTOR CO.
  43. Connect the transmission range (TR) sensor electrical connector.
    44. Fig 40: Locating Transmission Range (TR) Sensor Electrical Connector
    G03897857Courtesy of FORD MOTOR CO.
  44. Install the transaxle control cable, bracket and bolts.
    • Tighten to 19 Nm (14 lb-ft).
    • Attach the wiring harness pin-type retainers.
    45. Fig 41: Transaxle Control Cable & Bracket
    GF0024116Courtesy of FORD MOTOR CO.
  45. Connect the shift cable to the transaxle manual lever.
    46. Fig 42: Locating Shift Cable End At Manual Lever
    G03897855Courtesy of FORD MOTOR CO.
  46. Connect the transaxle electrical connector.
    47. Fig 43: Transaxle Electrical Connector
    GF0024115Courtesy of FORD MOTOR CO.
  47. Attach the wiring harness retainers to the battery tray bracket.
    48. Fig 44: Wiring Harness Retainers
    GF0024114Courtesy of FORD MOTOR CO.
  48. Connect the 42-pin electrical connector and tighten the bolt. Install the ground strap and bolt.
    • Tighten to 10 Nm (89 lb-in).
    49. Fig 45: Locating Ground Strap & Electrical Connector
    G03897852Courtesy of FORD MOTOR CO.
  49. Connect the electrical connector to the power distribution box.
    50. Fig 46: Power Distribution Box Electrical Connector
    GF0024113Courtesy of FORD MOTOR CO.
  50. Connect the cables and install the nuts.
    • Tighten to 12 Nm (9 lb-ft).
    51. Fig 47: Locating Cables & Nuts
    G03897850Courtesy of FORD MOTOR CO.
  51. Install the power distribution box cover.
    52. Fig 48: Locating Power Distribution Box Cover
    G03897849Courtesy of FORD MOTOR CO.
  52. If equipped, install the ground eyelet and bolt.
    • Tighten to 10 Nm (89 lb-in).
    53. Fig 49: Ground Eyelet & Bolt
    GF0024112Courtesy of FORD MOTOR CO.

    Front wheel drive (FWD) vehicles 

  53. Install the front drive intermediate halfshaft. For additional information, refer to FRONT DRIVE HALFSHAFTS article.
  54. Install the lateral support crossmember and bolts.
    • Tighten to 115 Nm (85 lb-ft).
    55. Fig 50: Identifying Lateral Support Crossmember And Bolts
    G03897847Courtesy of FORD MOTOR CO.

    All wheel drive (AWD) vehicles 

  55. Install the transfer case. For additional information, refer to TRANSFER CASE - POWER TRANSFER UNIT (PTU) article.

    56. All vehicles 

  56. Install the LH front drive halfshaft. For additional information, refer to FRONT DRIVE HALFSHAFTS article.
  57. Install the generator shield and the nut and the pin-type retainer and attach the wire retainers.
    • Tighten to 20 Nm (15 lb-ft).
    58. Fig 51: Generator Shield
    GF0024111Courtesy of FORD MOTOR CO.
  58. Install the lower air duct and install the bolt.
    • Tighten to 4 Nm (35 lb-in).
    59. Fig 52: Lower Air Duct
    GF0024110Courtesy of FORD MOTOR CO.
  59. Install the accessory drive belt tensioner. For additional information, refer to ACCESSORY DRIVE - 2.3L article.
  60. Connect the heated oxygen sensor (HO2S) and the catalyst monitor sensor electrical connectors.
    61. Fig 53: Heated Oxygen Sensor (HO2S) And Catalyst Monitor Sensor Electrical Connectors
    GF0024109Courtesy of FORD MOTOR CO.
  61. Install the exhaust flexible pipe. For additional information, refer to EXHAUST SYSTEM article.
  62. Install the starter. For additional information, refer to STARTING SYSTEM article.
  63. Install the battery tray and battery. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
  64. Install the engine air cleaner and air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - 2.3L article.
  65. Fill the engine with clean engine oil.
  66. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING article.
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