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Engine - Automatic Transaxle: Material

WARNING: This page is about a different car, the 2010 Mercury Mariner and 2010 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
MATERIAL SPECIFICATION

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, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

All vehicles 

  1. Using the Heavy Duty Floor 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 the 4 new torque converter nuts.
    • Tighten to 35 Nm (26 lb-ft).
      Fig 1: Locating Torque Converter Nuts
      G06097288Courtesy of FORD MOTOR CO.
  3. Using the Powertrain Lift and Universal Adapter Brackets, position the engine and transaxle onto the Powertrain Lift.
    Fig 2: Identifying Powertrain Lift And Universal Adapter Brackets
    G06095071Courtesy of FORD MOTOR CO.

    All-Wheel Drive (AWD) vehicles 

  4. Using the Handle and PTO Driven Gear Oil Seal Installer, install the intermediate shaft seal.
    Fig 3: Installing Intermediate Shaft Seal
    G06095387Courtesy of FORD MOTOR CO.
  5. Install the Power Transfer Unit (PTU) heat shield and the 3 bolts.
    • Tighten to 11 Nm (97 lb-in).
      Fig 4: Locating PTU Heat Shield And Bolts
      G06095083Courtesy of FORD MOTOR CO.
  6. Install the PTU  and the 3 RH PTU  bolts.
    • Tighten to 70 Nm (52 lb-ft).
      Fig 5: Locating RH PTU Bolts And PTU
      G06095082Courtesy of FORD MOTOR CO.
  7. Install the LH lower PTU  bolt.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 6: Locating LH Lower PTU Bolt
      G06095081Courtesy of FORD MOTOR CO.
  8. Attach the PTU  vent hose.
    Fig 7: Locating PTU Vent Hose
    G06383267Courtesy of FORD MOTOR CO.

    All vehicles 

  9. Install the starter motor isolator.
    Fig 8: Identifying Starter Motor Isolator
    G06097287Courtesy of FORD MOTOR CO.
  10. Install the starter motor and the 2 stud bolts.
    • Tighten to 35 Nm (26 lb-ft).
      Fig 9: Locating Starter Stud Bolts
      G06095078Courtesy of FORD MOTOR CO.
  11. Install the ground wire and the nut.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 10: Locating Ground Wire Nut
      G06095077Courtesy of FORD MOTOR CO.
  12. Install the starter motor harness connectors.
    1. Install the starter motor solenoid battery nut.
      • Tighten to 12 Nm (106 lb-in).
    2. Install the starter motor solenoid nut.
      • Tighten to 5 Nm (44 lb-in).
        Fig 11: Identifying Battery Cable Nut And Starter Solenoid Terminal Nut
        G06095076Courtesy of FORD MOTOR CO.
  13. Raise the engine and transaxle into the vehicle.
  14. Install the bolt in the LH transaxle mount.
    • Tighten to 103 Nm (76 lb-ft).
      Fig 12: Locating LH Transaxle Mount Bolt
      G06095075Courtesy of FORD MOTOR CO.
    15. NOTE: Late build AWD  vehicle equipped with a mass damper shown, other vehicles similar.
  15. Install the bolt in the rear transaxle mount and mass damper (if equipped).
    • Tighten to 115 Nm (85 lb-ft).
      Fig 13: Locating Transaxle Rear Mount And Mass Damper
      G06382954Courtesy of FORD MOTOR CO.
  16. Install the engine mount bracket and nuts.
    • Tighten to 115 Nm (85 lb-ft).
      Fig 14: Locating Engine Mount Bracket Nuts
      G06095073Courtesy of FORD MOTOR CO.
  17. Install the engine mount bracket bolt.
    • Tighten to 115 Nm (85 lb-ft).
      Fig 15: Locating Engine Mount Bracket Bolt
      G06095072Courtesy of FORD MOTOR CO.
  18. Install a new spin-on engine oil filter.
    • Lubricate the spin-on oil filter gasket with clean engine oil and tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter adapter.
      Fig 16: Locating Engine Oil Filter
      G06095070Courtesy of FORD MOTOR CO.

    AWD vehicles 

  19. Install the PTU  bracket and the 2 PTU  bracket-to- PTU  bolts.
    • Tighten to 45 Nm (33 lb-ft).
      Fig 17: Locating PTU Bracket Bolts
      G06383277Courtesy of FORD MOTOR CO.
  20. Install the PTU  bracket-to-engine bolt.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 18: Locating PTU Bracket-To-Engine Bolt
      G06097276Courtesy of FORD MOTOR CO.
  21. Install the 4 PTU  bracket-to-engine bolts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 19: Locating PTU Bracket-To-Engine Bolts
      G06097275Courtesy of FORD MOTOR CO.
    22. NOTE: A new Power Transfer Unit (PTU) intermediate shaft seal must be installed whenever the intermediate shaft or PTU  is removed from the vehicle.
  22. Install a new intermediate shaft seal and deflector. For additional information, refer to TRANSFER CASE-POWER TRANSFER UNIT (PTU) .
  23. If equipped, install the dampener and the 3 bolts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 20: Locating Bolts And Dampener
      G06097280Courtesy of FORD MOTOR CO.
  24. Install the 2 transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 21: Locating Transaxle-To-Engine Bolts
      G06095066Courtesy of FORD MOTOR CO.
  25. Install the 2 transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 22: Locating Transaxle-To-Engine Bolts
      G06095065Courtesy of FORD MOTOR CO.
  26. Install the engine support crossmember and new nut.
    • Tighten to 175 Nm (129 lb-ft).
      Fig 23: Identifying Cross Brace And Rear Nut
      G06097243Courtesy of FORD MOTOR CO.
  27. 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).
      Fig 24: Locating Front Roll Restrictor Bolt And Engine Support Crossmember Bolts
      G06097242Courtesy of FORD MOTOR CO.
  28. Connect the lower radiator hose to the radiator.
    Fig 25: Locating Lower Radiator Hose At Radiator
    G06095061Courtesy of FORD MOTOR CO.
  29. Install the A/C compressor and connect the A/C compressor electrical connector.
    • Attach the wire harness retainer.
    • Tighten the bolts to 25 Nm (18 lb-ft).
      Fig 26: Locating A/C Compressor Electrical Connector And Bolts
      G06095060Courtesy of FORD MOTOR CO.
  30. Attach the 2 retainers and connect the generator electrical connector.
    Fig 27: Locating Generator Electrical Connector And Retainers
    G06095059Courtesy of FORD MOTOR CO.
  31. Connect the engine control harness electrical connector.
    Fig 28: Locating Engine Control Harness Electrical Connector
    G06095058Courtesy of FORD MOTOR CO.
  32. Connect the PCM electrical connector and attach the wire harness retainer.
    Fig 29: Locating PCM Center Electrical Connector
    G06095057Courtesy of FORD MOTOR CO.
  33. Connect the fuel supply tube quick connect coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
    Fig 30: Locating Fuel Supply Tube Quick Connect Coupling
    G06095056Courtesy of FORD MOTOR CO.
  34. Connect the fuel vapor return tube.
    • Attach the fuel vapor tube retainer to the wire harness.
      Fig 31: Locating Fuel Vapor Tube Retainer
      G06095055Courtesy of FORD MOTOR CO.
  35. Connect the vacuum supply tube.
    Fig 32: Locating Vacuum Supply Tube
    G06095054Courtesy of FORD MOTOR CO.
  36. Connect the heater hoses to the heater core.
    Fig 33: Locating Heater Hoses At Heater Core
    G06095053Courtesy of FORD MOTOR CO.
  37. Attach the heater hose support strap to the stud.
    Fig 34: Locating Heater Hose Support Strap Stud
    G06095052Courtesy of FORD MOTOR CO.
  38. Connect the upper radiator hose.
    Fig 35: Locating Upper Radiator Hose
    G06095051Courtesy of FORD MOTOR CO.
  39. If equipped, route the block heater wiring harness and attach all retainers. Connect the block heater electrical connector.
    Fig 36: Identifying Block Heater Electrical Connector
    G06095050Courtesy of FORD MOTOR CO.
  40. Attach the shift cable pin-type retainer.
    Fig 37: Locating Shift Cable Pin-Type Retainer
    G06095049Courtesy of FORD MOTOR CO.
  41. Attach the shift cable to the shift cable bracket.
    Fig 38: Locating Transmission Shift Cable Tabs
    G06382928Courtesy of FORD MOTOR CO.
  42. Connect the shift cable to the transaxle manual lever.
    Fig 39: Locating Transaxle Manual Lever Shift Cable
    G06095047Courtesy of FORD MOTOR CO.
  43. Attach the 2 wiring harness retainers to the battery tray bracket.
    Fig 40: Locating Wiring Harness Retainers On Battery Tray Bracket
    G06095046Courtesy of FORD MOTOR CO.
  44. Install the ground strap and bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 41: Locating Ground Strap Bolt
      G06095045Courtesy of FORD MOTOR CO.
  45. Connect the electrical connector to the Power Distribution Box (PDB).
    Fig 42: Locating Electrical Connector From Power Distribution Box
    G06095044Courtesy of FORD MOTOR CO.
  46. Connect the cable to the PDB and install the nut.
    • Tighten to 12 Nm (106 lb-in).
      Fig 43: Locating PDB Cable Nut
      G06095043Courtesy of FORD MOTOR CO.
  47. Install the PDB cover.
    Fig 44: Locating Power Distribution Box Cover
    G06095042Courtesy of FORD MOTOR CO.
  48. Connect the 2 transaxle fluid cooler tubes.
    Fig 45: Locating Transaxle Fluid Cooler Tubes
    G06095429Courtesy of FORD MOTOR CO.
  49. Install the 2 secondary latches to the transaxle fluid cooler tubes.
    Fig 46: Locating Secondary Latches
    G06097282Courtesy of FORD MOTOR CO.
  50. Connect the Turbine Shaft Speed (TSS) sensor electrical connector.
    Fig 47: Locating Turbine Shaft Speed (TSS) Sensor Electrical Connector
    G06097285Courtesy of FORD MOTOR CO.
  51. Attach the wiring harness retainer to the transaxle stud bolt.
    Fig 48: Locating Transaxle Control Wire Harness Retainer
    G06073946Courtesy of FORD MOTOR CO.
  52. Connect the transaxle electrical connector.
    Fig 49: Locating Transaxle Electrical Connector
    G06095037Courtesy of FORD MOTOR CO.
  53. If equipped, install the ground eyelet and bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 50: Locating Ground Eyelet Bolt
      G06095036Courtesy of FORD MOTOR CO.

    AWD vehicles 

  54. Position the driveshaft to the PTU  and install the 6 bolts.
    • Tighten to 37 Nm (27 lb-ft).
      Fig 51: Locating Driveshaft And Bolts
      G06097268Courtesy of FORD MOTOR CO.

    All vehicles 

  55. Install the generator air duct and make sure the tab is latched.
    Fig 52: Locating Locking Tab And Generator Air Duct
    G06095034Courtesy of FORD MOTOR CO.
  56. Install the accessory drive belt. For additional information, refer to ACCESSORY DRIVE - 2.5L .
  57. Install the intermediate shaft.
    Fig 53: Locating Intermediate Shaft
    G06095033Courtesy of FORD MOTOR CO.
  58. Install the 2 intermediate shaft bearing retainer nuts.
    • Tighten to 27 Nm (20 lb-ft).
      Fig 54: Identifying Intermediate Shaft Retaining Nuts
      G06095032Courtesy of FORD MOTOR CO.
  59. Install the exhaust downpipe and exhaust intermediate pipe. For additional information, refer to EXHAUST SYSTEM .
  60. Install the lateral support crossmember and bolts.
    • Tighten to 115 Nm (85 lb-ft).
      Fig 55: Locating Lateral Support Crossmember And Bolts
      G06095031Courtesy of FORD MOTOR CO.
  61. Install the RH and LH halfshafts. For additional information, refer to FRONT DRIVE HALFSHAFTS .
  62. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  63. Install the engine Air Cleaner (ACL) and ACL  outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING - 2.5L .
  64. Fill the engine with clean engine oil.
  65. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING .
  66. Check and fill the transmission fluid as necessary. For additional information, refer to GENERAL PROCEDURES .

    AWD vehicles 

  67. Check and fill the PTU  fluid as necessary. For additional information, refer to TRANSFER CASE-POWER TRANSFER UNIT (PTU) .
  68. If the engine was disassembled, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.
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