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Transaxle - 2.5L: Removal

WARNING: This page is about a different car, the 2010 Mercury Milan and 2010 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Remove the Air Cleaner (ACL) and the outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING - 2.5L .
  3. Remove the battery and battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  4. Disconnect the selector lever cable end from the manual control lever.
    Fig 1: Locating Selector Lever Cable
    G06278618Courtesy of FORD MOTOR CO.
  5. Remove the 2 nuts and position the selector lever cable and bracket aside.
    Fig 2: Locating Nuts And Bracket
    G06278619Courtesy of FORD MOTOR CO.
  6. Disconnect the wiring harness retainers from the main control cover studbolts.
    Fig 3: Locating Wiring Harness Retainers
    G06278620Courtesy of FORD MOTOR CO.
  7. Remove the 3 top bellhousing bolts.
    Fig 4: Locating Top Bellhousing Bolts
    G06278621Courtesy of FORD MOTOR CO.
  8. Remove the subframe. For additional information, refer to UNI-BODY, SUBFRAME AND MOUNTING SYSTEM .
  9. Remove the 2 roll restrictor bracket bolts.
    Fig 5: Locating Roll Restrictor Bracket Bolts
    G06278622Courtesy of FORD MOTOR CO.
  10. Install the Engine Support Bar and support the engine and transaxle.
    Fig 6: Identifying Engine Support Bar And Support
    G06278623Courtesy of FORD MOTOR CO.
  11. Remove the transaxle support insulator through bolt and lower the transaxle 19 mm (0.748 in).
    Fig 7: Locating Transaxle Support Insulator Through Bolt
    G06278624Courtesy of FORD MOTOR CO.
  12. Remove the 3 nuts, the bolt and remove the transaxle support insulator bracket.
    Fig 8: Locating Nuts, Bolt And Transaxle Support Insulator Bracket
    G06278625Courtesy of FORD MOTOR CO.
  13. NOTE: If transaxle disassembly or installation of a new transaxle is necessary, drain the transmission fluid.

    Remove the drain plug and allow the transmission fluid to drain.

    Fig 9: Locating Transmission Fluid Drain Plug
    G06278626Courtesy of FORD MOTOR CO.
  14. Install the transmission fluid drain plug.
    • Tighten to 12 Nm (106 lb-in).
    Fig 10: Locating Transmission Fluid Drain Plug
    G06278627Courtesy of FORD MOTOR CO.
  15. Remove the LH halfshaft and intermediate shaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
  16. Remove the starter motor. For additional information, refer to STARTING SYSTEM .
  17. Remove the rubber insulator from the bellhousing.
    Fig 11: Locating Rubber Insulator
    G06278628Courtesy of FORD MOTOR CO.
  18. NOTE: Only rotate the engine in a clockwise direction or engine damage will occur.
    NOTE: Mark one stud and the flexplate for assembly reference.

    Remove and discard the 4 torque converter nuts.

    Fig 12: Locating Torque Converter Nuts
    G06278629Courtesy of FORD MOTOR CO.
  19. Disconnect the transaxle main electrical connector.
    Fig 13: Locating Transaxle Main Electrical Connector
    G06278630Courtesy of FORD MOTOR CO.
  20. Disconnect the Turbine Shaft Speed (TSS) electrical connector.
    Fig 14: Locating Turbine Shaft Speed (TSS) Sensor Electrical Connector
    G06278631Courtesy of FORD MOTOR CO.
  21. Remove the transmission fluid cooler tube secondary latches.
    Fig 15: Locating Transmission Fluid Cooler Tube Secondary Latches
    G06278632Courtesy of FORD MOTOR CO.
  22. Using the Transmission Cooler Line Disconnect Tool, disconnect the transmission fluid cooler tubes.
    Fig 16: Locating Transmission Fluid Cooler Tubes
    G06278633Courtesy of FORD MOTOR CO.
  23. Support the transaxle with a suitable transmission jack.
  24. Remove the 3 rear torque converter housing bolts.
    Fig 17: Locating Rear Torque Converter Housing Bolts
    G06278634Courtesy of FORD MOTOR CO.
  25. Remove the 4 front torque converter housing bolts.
    Fig 18: Locating Front Torque Converter Housing Bolts
    G06278635Courtesy of FORD MOTOR CO.
  26. Separate the transaxle from the engine and install the Torque Converter Retainer.
    Fig 19: Identifying Torque Converter Retainer
    G06278636Courtesy of FORD MOTOR CO.
  27. Remove the transaxle from the vehicle.
  28. Remove the transmission fluid level indicator.
    Fig 20: Locating Transmission Fluid Level Indicator
    G06278637Courtesy of FORD MOTOR CO.
  29. Remove the transmission fluid filler tube nut.
    Fig 21: Locating Transmission Fluid Filler Tube Nut
    G06278638Courtesy of FORD MOTOR CO.
  30. Remove the transaxle vent tube from the transaxle case and remove the transmission fluid filler tube.
    Fig 22: Locating Transaxle Vent Tube
    G06278639Courtesy of FORD MOTOR CO.
  31. Open the transmission fluid cooler tube retainers.
    Fig 23: Locating Transmission Fluid Cooler Tube Retainers
    G06278640Courtesy of FORD MOTOR CO.
  32. Remove the 2 secondary latches.
    Fig 24: Locating Secondary Latches
    G06278641Courtesy of FORD MOTOR CO.
  33. Using the Transmission Cooler Line Disconnect Tool, disconnect and remove the transmission fluid cooler tubes from the transaxle.
    Fig 25: Identifying Transmission Cooler Line Disconnect Tool
    G06278642Courtesy of FORD MOTOR CO.
  34. Remove the 2 nuts and remove the transmission fluid cooler tube bracket.
    Fig 26: Locating Nuts And Transmission Fluid Cooler Tube Bracket
    G06278643Courtesy of FORD MOTOR CO.
  35. If installing a new transaxle or overhauling the transaxle, the transmission fluid cooler will need to be backflushed and cleaned. Carry out transmission fluid cooler backflushing and cleaning. For additional information, refer to TRANSMISSION FLUID COOLER BACKFLUSHING AND CLEANING . Clean the transaxle-mounted transmission fluid cooler tubes by hand.
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