Transaxle - 2.3L: Installation

All vehicles 

1. Lubricate the torque converter pilot hub with grease.
Fig 1: Identifying Torque Converter Pilot Hub
Courtesy of FORD MOTOR CO.
2. Rotate the torque converter to place the paint dot in the 6 o'clock position.
3. Install the special tool.
Fig 2: Identifying Special Tool
Courtesy of FORD MOTOR CO.
4. Position the transaxle in place.
Fig 3: Lowering Transaxle From Engine Compartment
Courtesy of FORD MOTOR CO.
5. Once the transaxle is in place, prior to bolting it to the engine, remove the special tool.
Fig 4: Identifying Special Tool
Courtesy of FORD MOTOR CO.
6. Move the transaxle assembly toward the engine assembly and install the 4 bolts.
   • Tighten to 40 Nm (30 lb-ft).
Fig 5: Locating Transaxle-To-Engine Bolts
Courtesy of FORD MOTOR CO.
7. Install the transaxle retaining bolts.
   • Tighten to 40 Nm (30 lb-ft).
Fig 6: Locating Rear Bellhousing Bolts
Courtesy of FORD MOTOR CO.
8. Install 4 new torque converter nuts.
   • Tighten to 40 Nm (30 lb-ft).
Fig 7: Locating Torque Converter Nut
Courtesy of FORD MOTOR CO.
9. Install the transmission fluid cooler tube.
   • Tighten to 23 Nm (17 lb-ft).
Fig 8: Locating Transmission Fluid Cooler Tube
Courtesy of FORD MOTOR CO.
10. Install the output shaft speed (OSS) sensor.
    • Tighten to 12 Nm (9 lb-ft).
Fig 9: Locating OSS Sensor Bolt
Courtesy of FORD MOTOR CO.
11. Install the fluid cooler tube.
    1. Connect the OSS sensor.
    2. Connect the turbine shaft speed (TSS) sensor (white connector).
       • Connect the wiring harness retainer to the transmission case.
    3. Install the fluid cooler tube.
       • Tighten to 23 Nm (17 lb-ft).
    4. Install the fluid cooler bolt.
       • Tighten to 13 Nm (10 lb-ft).
Fig 10: Identifying Fluid Cooler Tube Components
Courtesy of FORD MOTOR CO.
12. Install the starter motor isolator.
Fig 11: Identifying Starter Motor Isolator
Courtesy of FORD MOTOR CO.
13. Install the starter motor.
    • Tighten to 35 Nm (26 lb-ft).
Fig 12: Locating Starter Motor Bolts
Courtesy of FORD MOTOR CO.
14. Install the starter motor harness connector.
    1. Install the starter motor solenoid battery nut.
       • Tighten to 10 Nm (89 lb-in).
    2. Install the starter motor solenoid nut.
       • Tighten to 7 Nm (62 lb-in).
Fig 13: Identifying Battery Cable & Starter Solenoid Terminal Nut
Courtesy of FORD MOTOR CO.
15. Install the wire harness clip retainer and the ground wire to starter bolts.
    • Tighten to 27 Nm (20 lb-ft).
Fig 14: Locating Wire Harness Clip Retainer & Starter Bolts
Courtesy of FORD MOTOR CO.
16. Install the lower front mount bracket.
    • Tighten to 55 Nm (41 lb-ft).
Fig 15: Locating Transaxle Front Mount Plate Bolts
Courtesy of FORD MOTOR CO.
17. Using the special tools, raise the transaxle.
Fig 16: Raising Transaxle
Courtesy of FORD MOTOR CO.
18. Install the LH upper transaxle mount through bolt.
    • Tighten to 103 Nm (76 lb-ft).
Fig 17: Locating LH Transaxle Mount Through Bolt
Courtesy of FORD MOTOR CO.
19. Remove the special tools.
Fig 18: Removing Special Tools
Courtesy of FORD MOTOR CO.
20. Remove the special tools.
Fig 19: Removing Special Tools
Courtesy of FORD MOTOR CO.
21. Install the upper transaxle bolts.
    • Tighten to 40 Nm (30 lb-ft).
Fig 20: Locating Upper Transaxle Bolts
Courtesy of FORD MOTOR CO.
22. Connect the transmission range (TR) sensor electrical connector.
Fig 21: Locating Transmission Range (TR) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
23. Connect the shift cable to the manual lever and install the 2 bolts.
    • Tighten to 23 Nm (17 lb-ft).
Fig 22: Locating Shift Cable Manual Lever Bolts
Courtesy of FORD MOTOR CO.
24. Install the wire harness bracket nut and plug in the bulkhead electrical connector.
    • Tighten to 10 Nm (89 lb-in).
Fig 23: Locating Wire Harness Bracket Nut & Plug
Courtesy of FORD MOTOR CO.
25. Install the rear transmission mount.
    • Tighten to 80 Nm (59 lb-ft).
Fig 24: Locating Rear Transmission Mount Bolts
Courtesy of FORD MOTOR CO.
26. Install the rear transaxle mount through bolt.
    • Tighten to 120 Nm (89 lb-ft).
Fig 25: Locating Rear Transaxle Mount Bolt
Courtesy of FORD MOTOR CO.

Front wheel drive (FWD) vehicles 

27. Install the dampener.
    • Tighten to 40 Nm (30 lb-ft).
Fig 26: Locating Bolts & Dampener
Courtesy of FORD MOTOR CO.

All wheel drive (AWD) vehicles 

28. Install the power transfer unit (PTU) assembly.
    • Tighten to 45 Nm (33 lb-ft).
Fig 27: Locating PTU Bolts
Courtesy of FORD MOTOR CO.
29. Position the driveshaft in place and install the nuts.
    • Tighten to 48 Nm (35 lb-ft).
Fig 28: Locating Center Bearing Nuts
Courtesy of FORD MOTOR CO.
30. Install the driveshaft.
    • Tighten to 20 Nm (15 lb-ft).
Fig 29: Locating Driveshaft & Bolts
Courtesy of FORD MOTOR CO.

All vehicles 

31. Install the bracket.
    • Tighten to 55 Nm (41 lb-ft).
Fig 30: Locating Engine Mounting Bracket Bolts
Courtesy of FORD MOTOR CO.
32. Install the front nuts on the exhaust-to-intermediate shaft bracket.
    • Tighten to 30 Nm (22 lb-ft).
Fig 31: Locating Exhaust-To-Intermediate Shaft Bracket Nuts
Courtesy of FORD MOTOR CO.
33. Install the bolts on the rear of the exhaust-to-intermediate shaft bracket.
    • Tighten to 30 Nm (22 lb-ft).
Fig 32: Locating Bolts On Rear Of Exhaust-To-Intermediate Shaft Bracket
Courtesy of FORD MOTOR CO.
34. Install the flexpipe on the exhaust manifold and install the nuts.
    • Tighten to 25 Nm (18 lb-ft).
Fig 33: Locating Flexpipe On Exhaust Manifold & Nuts
Courtesy of FORD MOTOR CO.
35. Install the intermediate shaft.
Fig 34: Locating Intermediate Shaft
Courtesy of FORD MOTOR CO.
36. Install the intermediate shaft retaining nuts.
    • Tighten to 27 Nm (20 lb-ft).
Fig 35: Locating Intermediate Shaft Retaining Nuts
Courtesy of FORD MOTOR CO.
37. Install the LH and RH halfshafts and frame bolts.
    • Tighten to 115 Nm (85 lb-ft).
Fig 36: LH & RH Control Arm Frame Bolt
Courtesy of FORD MOTOR CO.
38. Using the special tool, install the LH halfshaft into the wheel knuckle.
Fig 37: Installing LH Half Shaft Into Wheel Knuckle Using Special Tools
Courtesy of FORD MOTOR CO.
39. Install the LH hub nut.
    • Tighten to 290 Nm (214 lb-ft).
Fig 38: Locating LH Front Axle Wheel Hub Nut
Courtesy of FORD MOTOR CO.
40. Install the cross brace and the rear nut.
    • Tighten to 175 Nm (129 lb-ft).
Fig 39: Identifying Cross Brace And Rear Nut
Courtesy of FORD MOTOR CO.
41. Install the 2 bolts for the brace.
    • Tighten to 90 Nm (66 lb-ft).
Fig 40: Locating Bolts For Brace
Courtesy of FORD MOTOR CO.
42. Install the bolt for the mount.
    • Tighten to 115 Nm (85 lb-ft).
Fig 41: Locating Bolt For Mount
Courtesy of FORD MOTOR CO.
43. Install the cross brace and the 4 bolts.
    • Tighten to 115 Nm (85 lb-ft).
Fig 42: Locating Cross Brace & Bolts
Courtesy of FORD MOTOR CO.
44. Install the LH splash shield and the 7 retainers.
Fig 43: View Of LH Splash Shield And Retainers
Courtesy of FORD MOTOR CO.
45. Install the RH splash shield and the 5 retainers.
Fig 44: Locating RH Splash Shield & Retainers
Courtesy of FORD MOTOR CO.

AWD vehicles 

46. Install the vent tube to the fluid level indicator.
Fig 45: Locating Power Transfer Unit (PTU) Vent Hose
Courtesy of FORD MOTOR CO.

All vehicles 

47. Install the air cleaner assembly.
    1. Install the bolt.
       • Tighten to 10 Nm (89 lb-in).
    2. Connect the mass air flow (MAF) sensor.
    3. Connect the brake booster vacuum hose.
    4. Connect the wiring harness retainer.
    5. Connect the breather tube.
    6. Tighten the air cleaner clamp.
Fig 46: Identifying Air Cleaner Assembly
Courtesy of FORD MOTOR CO.
48. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
49. Fill the transaxle with clean automatic transmission fluid.
50. Verify that the shift cable is correctly adjusted. The vehicle should start in PARK and REVERSE and the reverse lamps should illuminate in REVERSE. For additional information, refer to AUTOMATIC TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS - CD4E article.
51. Check the fluid level and correct as necessary.