Transaxle - 3.0L

Illustration	Tool Name	Tool Number
	Adapter for 303-290-A (Support Leg)	303-290A-03A
	Support Bar, Engine	303-290A
	Adapters for 303-290	303-290A-01
	Engine Lifting Chains (Part of Spreader Bar)	303-D089 (D93P-6001-A3) or equivalent
	Alignment Gauge, TR Sensor	307-351 (T97L-70010-A)
	Retainer, Torque Converter	307-346 (T97T-7902-A)

All vehicles 

1. Install the mount bracket.
   • Tighten to 90 Nm (66 lb-ft).
Fig 1: Locating Transaxle Mount Bracket
Courtesy of FORD MOTOR CO.
2. Lubricate the torque converter pilot hub with grease.
Fig 2: Identifying Torque Converter Pilot Hub
Courtesy of FORD MOTOR CO.
3. Install the special tool.
Fig 3: Identifying Special Tool
Courtesy of FORD MOTOR CO.
4. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING article.
5. Position the transaxle in place.
Fig 4: Lowering Transaxle From Engine Compartment
Courtesy of FORD MOTOR CO.
6. Once the transaxle is in place, prior to bolting it to the engine, remove the special tool.
Fig 5: Identifying Special Tool
Courtesy of FORD MOTOR CO.
7. Move the transaxle assembly toward the engine assembly and install the bolt.
   • Tighten to 40 Nm (30 lb-ft).
Fig 6: Locating Bolt
Courtesy of FORD MOTOR CO.
8. Install the transaxle bolt.
   • Tighten to 40 Nm (30 lb-ft).
Fig 7: Locating Transaxle Bolt
Courtesy of FORD MOTOR CO.
9. Install the lower transaxle bolts.
   • Tighten to 48 Nm (35 lb-ft).
Fig 8: Locating Lower Transaxle Bolts
Courtesy of FORD MOTOR CO.
10. Install 4 new torque converter nuts.
    • Tighten to 40 Nm (30 lb-ft).
Fig 9: Locating Torque Converter Nuts
Courtesy of FORD MOTOR CO.
11. Install the access cover.
Fig 10: Locating Access Cover
Courtesy of FORD MOTOR CO.
12. Install the transmission fluid cooler tube.
    • Tighten to 23 Nm (17 lb-ft).
Fig 11: Locating Transmission Fluid Cooler Tube
Courtesy of FORD MOTOR CO.
13. Install the output shaft speed (OSS) sensor.
    • Tighten to 12 Nm (9 lb-ft).
Fig 12: Locating OSS Sensor Bolt
Courtesy of FORD MOTOR CO.
14. Install the fluid cooler tube.
    1. Connect the OSS sensor.
    2. Connect the turbine shaft speed (TSS) sensor (white connector).
    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 13: Identifying Fluid Cooler Tube Components
Courtesy of FORD MOTOR CO.
15. Raise the transaxle enough to install the lower cross brace.
Fig 14: Identifying Special Tools
Courtesy of FORD MOTOR CO.
16. Lower the engine onto the RH engine mount.
Fig 15: Locating Lowering Engine Onto RH Engine Mount
Courtesy of FORD MOTOR CO.
17. Install the rear transaxle mount bolt.
    • Tighten to 120 Nm (89 lb-ft).
Fig 16: Locating Rear Transaxle Mount Bolt
Courtesy of FORD MOTOR CO.
18. Vehicles not equipped with a power transfer unit (PTU), install the dampener.
19. Install the rear transaxle mount and install the bolt.
    • Tighten to 40 Nm (30 lb-ft).
Fig 17: Locating Transfer Case Bolt & Transfer Case Unit
Courtesy of FORD MOTOR CO.

All wheel drive (AWD) vehicles 

20. Install the PTU bolts.
    • Tighten to 45 Nm (33 lb-ft).
Fig 18: Locating PTU Bolts
Courtesy of FORD MOTOR CO.

All vehicles 

21. Connect the electrical connectors to the lower mount bracket.
Fig 19: Locating Electrical Connectors From Lower Mount Bracket
Courtesy of FORD MOTOR CO.
22. Install the cross brace and the rear nut.
    • Tighten to 175 Nm (129 lb-ft).
Fig 20: Identifying Cross Brace And Rear Nut
Courtesy of FORD MOTOR CO.
23. Install the 2 bolts for the brace.
    • Tighten to 90 Nm (66 lb-ft).
Fig 21: Locating Bolts For Brace
Courtesy of FORD MOTOR CO.
24. Install the bolt for the mount.
    • Tighten to 115 Nm (85 lb-ft).
Fig 22: Locating Bolt For Mount
Courtesy of FORD MOTOR CO.
25. Install the bracket.
    • Tighten to 55 Nm (41 lb-ft).
Fig 23: Locating Bolts & Bracket
Courtesy of FORD MOTOR CO.
26. Install the RH catalytic converter. For additional information, refer to EXHAUST SYSTEM article.

AWD vehicles 

27. For vehicles equipped with a PTU, connect the rear driveshaft to the PTU. Install the PTU bolts.
    • Tighten to 37 Nm (27 lb-ft).
Fig 24: Locating Driveshaft & Bolts
Courtesy of FORD MOTOR CO.

All vehicles 

28. Install the exhaust pipe and connect the exhaust pipe flange.
    • Tighten to 29 Nm (21 lb-ft).
Fig 25: Rear Exhaust Pipe Flange & Nuts
Courtesy of FORD MOTOR CO.
29. Connect the front flange.
    • Tighten to 29 Nm (21 lb-ft).
Fig 26: Front Exhaust Pipe Flange Nuts
Courtesy of FORD MOTOR CO.
30. Install the exhaust pipe.
    1. Install the rubber hanger.
    2. Install the exhaust pipe and install the bolts.
       • Tighten to 29 Nm (21 lb-ft).
Fig 27: Exhaust Hanger & Nuts
Courtesy of FORD MOTOR CO.
31. Install the cross brace.
    • Tighten to 115 Nm (85 lb-ft).
Fig 28: Locating Cross Brace & Bolts
Courtesy of FORD MOTOR CO.
32. Install the intermediate shaft.
Fig 29: Locating Intermediate Shaft
Courtesy of FORD MOTOR CO.
33. Install the intermediate shaft retaining nuts.
    • Tighten to 27 Nm (20 lb-ft).
Fig 30: Locating Intermediate Shaft Retaining Nuts
Courtesy of FORD MOTOR CO.
34. Reconnect the heated oxygen sensor (HO2S) sensor wire to the oil pan bolt studs and connect the connector.
Fig 31: Locating HO2S Sensor Connector
Courtesy of FORD MOTOR CO.
35. Install the generator shield and install the bolt.
    • Tighten to 10 Nm (89 lb-in).
Fig 32: Locating Generator Shield & Bolt
Courtesy of FORD MOTOR CO.
36. Install the retainer for the generator shield.
Fig 33: Locating Retaining Screw For Generator Shield
Courtesy of FORD MOTOR CO.
37. Install the LH and RH halfshafts in the transaxle.
38. Connect the LH suspension.
    1. Install the lower ball joint into the knuckle and install the bolt.
       • Tighten to 63 Nm (46 lb-ft).
    2. Install the tie-rod end retaining nut.
       • Tighten to 55 Nm (41 lb-ft).
    3. Install a new tie-rod end nut cotter pin.
    4. Connect the sway bar link.
       • Tighten to 63 Nm (46 lb-ft).
Fig 34: Identifying LH Suspension Components
Courtesy of FORD MOTOR CO.
39. Connect the RH suspension.
    1. Install the lower ball joint into the knuckle and install the bolt.
       • Tighten to 63 Nm (46 lb-ft).
    2. Install the tie-rod end retaining nut.
       • Tighten to 55 Nm (41 lb-ft).
    3. Install a new tie-rod end nut cotter pin.
    4. Connect the sway bar link.
       • Tighten to 63 Nm (46 lb-ft).
Fig 35: Identifying RH Suspension Components
Courtesy of FORD MOTOR CO.
40. Install the LH splash shield and the 7 retainers.
Fig 36: View Of LH Splash Shield And Retainers
Courtesy of FORD MOTOR CO.
41. Install the RH splash shield and the 7 retainers.
Fig 37: Locating RH Splash Shield & Retainers
Courtesy of FORD MOTOR CO.
42. Install the bolt for the RH engine mount.
    • Tighten to 120 Nm (89 lb-ft).
Fig 38: Locating RH Upper Transaxle Mount Bolt
Courtesy of FORD MOTOR CO.
43. Tighten the LH upper transaxle mount assembly.
    1. Tighten the 4 nuts for the bracket.
       • Tighten to 40 Nm (30 lb-ft).
    2. Install the through bolt.
       • Tighten to 103 Nm (76 lb-ft).
Fig 39: Locating LH Upper Transaxle Mount Assembly Bolt
Courtesy of FORD MOTOR CO.
44. Install the upper transaxle retaining bolts.
    • Tighten to 40 Nm (30 lb-ft).
Fig 40: Locating Upper Transaxle Retaining Bolts
Courtesy of FORD MOTOR CO.
45. Remove the special tools.
Fig 41: Identifying Special Tools
Courtesy of FORD MOTOR CO.
46. Remove the special tools.
Fig 42: Identifying Installation Special Tool
Courtesy of FORD MOTOR CO.
47. Remove the special tools.
Fig 43: Drivetrain Support Tool
Courtesy of FORD MOTOR CO.
48. Connect the electrical connectors together and then connect them to the upper intake manifold.
Fig 44: Locating Electrical Connectors
Courtesy of FORD MOTOR CO.
49. Install the starter motor and install the bolts.
    • Tighten to 25 Nm (18 lb-ft).
Fig 45: Locating Starter Bolts & Starter Motor
Courtesy of FORD MOTOR CO.
50. Install the ground cable.
    • Tighten to 27 Nm (20 lb-ft).
Fig 46: Locating Ground Cable
Courtesy of FORD MOTOR CO.
51. Install the starter motor solenoid harness connector.
    1. Install the starter motor solenoid battery nut.
       • Tighten to 12 Nm (9 lb-ft).
    2. Install the starter motor solenoid nut.
       • Tighten to 5 Nm (44 lb-in).
Fig 47: Locating Starter Motor Harness Connector & Nut
Courtesy of FORD MOTOR CO.
52. Install the shift cable and the bracket.
    • Tighten to 23 Nm (17 lb-ft).
Fig 48: Locating Shift Cable Bracket & Bolts
Courtesy of FORD MOTOR CO.
53. Connect the shift cable to the manual lever.
Fig 49: Locating Shift Cable End At Manual Lever
Courtesy of FORD MOTOR CO.
54. Connect the wire harness to the battery hold-down bracket.
Fig 50: Locating Wire Harness Bracket
Courtesy of FORD MOTOR CO.

AWD vehicles 

55. Connect the evaporative emissions (EVAP) and PTU vent hose to the transmission filler tube bracket.
Fig 51: Locating EVAP & Power Transfer Unit (PTU) Vent Hoses
Courtesy of FORD MOTOR CO.

All vehicles 

56. Install the main control cover vent tube.
Fig 52: Locating Main Control Cover Vent Tube
Courtesy of FORD MOTOR CO.
57. Position the bracket in place and install the nut. Connect the transaxle harness connector.
    • Tighten to 10 Nm (89 lb-in).
Fig 53: Locating Transaxle Harness Connector & Nut
Courtesy of FORD MOTOR CO.
58. Connect the transmission range (TR) sensor.
Fig 54: Locating Transmission Range (TR) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
NOTE: If installing an exchange transaxle, the digital TR sensor must be aligned.
59. Using the special tool, align the digital TR sensor.
    • Tighten to 10 Nm (89 lb-in).
Fig 55: Aligning Digital TR Sensor
Courtesy of FORD MOTOR CO.
60. Install the air cleaner as an assembly.
    1. Install the air cleaner assembly.
    2. Connect the air intake tube.
    3. Install the retaining bolt.
       • Tighten to 10 Nm (89 lb-in).
    4. Install the breather tube.
    5. Connect the mass air flow (MAF) sensor electrical connector.
Fig 56: Identifying Air Cleaner Assembly
Courtesy of FORD MOTOR CO.
NOTE: Before installing the battery tray, check the vent tube hose for any obstructions, kinks or incorrect routing position.
61. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
62. Fill the transaxle with clean automatic transmission fluid.
63. 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.
64. Check the fluid level and correct as necessary.