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Transaxle - 3.0L: Installation

WARNING: This page is about a different car, the 2006 Mercury Mariner and 2006 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the mount bracket.
    • Tighten to 80 N.m (59 lb-ft).
      Fig 1: Locating Transaxle Mount Bracket
      G04620575Courtesy of FORD MOTOR CO.
  2. Lubricate the torque converter pilot hub with grease.
    Fig 2: Locating Torque Converter Pilot Hub
    G04620576Courtesy of FORD MOTOR CO.
  3. Install the special tool.
    Fig 3: Identifying Special Tool
    G03900854Courtesy of FORD MOTOR CO.
  4. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  5. Position the transaxle in place.
    Fig 4: Identifying Transaxle Position
    G04620578Courtesy 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
    G03900854Courtesy of FORD MOTOR CO.
  7. Move the transaxle assembly toward the engine assembly and install the bolt.
    • Tighten to 40 N.m (30 lb-ft).
      Fig 6: Locating Bolts
      G04620580Courtesy of FORD MOTOR CO.
  8. Install the transaxle bolt.
    • Tighten to 40 N.m (30 lb-ft).
      Fig 7: Locating Transaxle Bolt
      G04620581Courtesy of FORD MOTOR CO.
  9. Install the lower transaxle bolts.
    • Tighten to 48 N.m (35 lb-ft).
      Fig 8: Locating Lower Transaxle Bolts
      G04620582Courtesy of FORD MOTOR CO.
  10. Install 4 new torque converter nuts.
    • Tighten to 40 N.m (30 lb-ft).
      Fig 9: Locating Torque Converter Nuts
      G04620583Courtesy of FORD MOTOR CO.
  11. Install the access cover.
    Fig 10: Locating Access Cover
    G04620584Courtesy of FORD MOTOR CO.
  12. Install the transmission fluid cooler tube.
    • Tighten to 23 N.m (17 lb-ft).
      Fig 11: Locating Transmission Fluid Cooler Tube
      G03897859Courtesy of FORD MOTOR CO.
  13. Install the output shaft speed (OSS) sensor.
    • Tighten to 12 N.m (9 lb-ft).
      Fig 12: Locating OSS Sensor Bolt
      G03897862Courtesy 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 N.m (17 lb-ft).
    4. Install the fluid cooler bolt.
      • Tighten to 13 N.m (10 lb-ft).
        Fig 13: Identifying Fluid Cooler Tube Components
        G04620587Courtesy of FORD MOTOR CO.
  15. Raise the transaxle enough to install the lower cross brace.
    Fig 14: Identifying Special Tools
    G04620588Courtesy of FORD MOTOR CO.
  16. Lower the engine onto the RH engine mount.
    Fig 15: Locating Lowering Engine Onto RH Engine Mount
    G04620589Courtesy of FORD MOTOR CO.
  17. Install the rear transaxle mount bolt.
    • Tighten to 115 N.m (85 lb-ft).
      Fig 16: Locating Rear Transaxle Mount Bolt
      G04620590Courtesy of FORD MOTOR CO.
  18. Install the rear transaxle mount and install 1 bolt.
    • Tighten to 40 N.m (30 lb-ft).
      Fig 17: Locating Transfer Case Bolt & Transfer Case Unit
      G04620591Courtesy of FORD MOTOR CO.
  19. Install the PTO bolts.
    • Tighten to 45 N.m (33 lb-ft).
      Fig 18: Locating PTO Bolts
      G04620592Courtesy of FORD MOTOR CO.
  20. Connect the electrical connectors to the lower mount bracket.
    Fig 19: Locating Electrical Connectors From Lower Mount Bracket
    G04620593Courtesy of FORD MOTOR CO.
  21. Install the cross brace and a new nut.
    • Tighten to 150 N.m (111 lb-ft) (vehicles built through 10/2005).
    • Tighten to 175 N.m (129 lb-ft) (vehicles built after 10/2005).
      Fig 20: Identifying Cross Brace And Rear Nut
      G03897887Courtesy of FORD MOTOR CO.
  22. Install the 2 bolts for the brace.
    • Tighten to 90 N.m (66 lb-ft).
      Fig 21: Locating Bolts For Brace
      G04620595Courtesy of FORD MOTOR CO.
  23. Install the bolt for the mount.
    • Tighten to 115 N.m (85 lb-ft).
      Fig 22: Locating Bolt For Mount
      G04620596Courtesy of FORD MOTOR CO.
  24. Install the bracket.
    • Tighten to 55 N.m (41 lb-ft).
      Fig 23: Locating Bolts & Bracket
      G04620597Courtesy of FORD MOTOR CO.
  25. Install the RH catalytic converter. For additional information, refer to INSTALLATION .
  26. For vehicles equipped with a PTO, connect the rear driveshaft to the PTO. Install the PTO bolts.
    • Tighten to 37 N.m (27 lb-ft).
      Fig 24: Locating Driveshaft & Bolts
      G04620598Courtesy of FORD MOTOR CO.
  27. Install the exhaust pipe and connect the exhaust pipe flange.
    • Tighten to 29 N.m (21 lb-ft).
      Fig 25: Locating Exhaust Pipe Flange Bolts
      G04620599Courtesy of FORD MOTOR CO.
  28. Connect the front flange.
    • Tighten to 29 N.m (21 lb-ft).
      Fig 26: Disconnecting Front Exhaust Pipe Flange Bolts
      G04620600Courtesy of FORD MOTOR CO.
  29. Install the exhaust pipe.
    1. Install the rubber hanger.
    2. Install the exhaust pipe and install the bolts.
      • Tighten to 29 N.m (21 lb-ft).
        Fig 27: Identifying Exhaust Pipe
        G04620601Courtesy of FORD MOTOR CO.
  30. Install the cross brace.
    • Tighten to 115 N.m (85 lb-ft).
      Fig 28: Locating Cross Brace & Bolts
      G03900713Courtesy of FORD MOTOR CO.
  31. Install the intermediate shaft.
    Fig 29: Locating Intermediate Shaft
    G04620603Courtesy of FORD MOTOR CO.
  32. Install the intermediate shaft retaining nuts.
    • Tighten to 27 N.m (20 lb-ft).
      Fig 30: Locating Intermediate Shaft Retaining Nuts
      G04620604Courtesy of FORD MOTOR CO.
  33. Reconnect the HO2S sensor wire to the oil pan bolt studs and connect the connector.
    Fig 31: Locating HO2S Sensor Connector
    G04620605Courtesy of FORD MOTOR CO.
  34. Install the generator shield and install the bolt.
    • Tighten to 10 N.m (89 lb-in).
      Fig 32: Locating Generator Shield & Bolt
      G04620606Courtesy of FORD MOTOR CO.
  35. Install the retainer for the generator shield.
    Fig 33: Locating Retaining Screw For Generator Shield
    G04620607Courtesy of FORD MOTOR CO.
  36. Install the LH and RH half shafts in the transaxle.
  37. Connect the LH suspension.
    1. Install the lower ball joint into the knuckle and install the bolt.
      • Tighten to 70 N.m (52 lb-ft) (vehicles built through 10/2005).
      • Tighten to 63 N.m (46 lb-ft) (vehicles built after 10/2005).
    2. Install the tie rod end retaining nut.
      • Tighten to 55 N.m (52 lb-ft).
    3. Install a new tie rod end nut cotter pin.
    4. Connect the sway bar link.
      • Tighten to 63 N.m (46 lb-ft).
        Fig 34: Identifying LH Suspension Components
        G04620608Courtesy of FORD MOTOR CO.
  38. Connect the RH suspension.
    1. Install the lower ball joint into the knuckle and install the bolt.
      • Tighten to 70 N.m (52 lb-ft) (vehicles built through 10/2005).
      • Tighten to 63 N.m (46 lb-ft) (vehicles built after 10/2005).
    2. Install the tie rod end retaining nut.
      • Tighten to 55 N.m (52 lb-ft).
    3. Install a new tie rod end nut cotter pin.
    4. Connect the sway bar link.
      • Tighten to 63 N.m (46 lb-ft).
        Fig 35: Identifying RH Suspension Components
        G04620609Courtesy of FORD MOTOR CO.
  39. Install the LH splash shield and the 7 retainers.
    Fig 36: View Of LH Splash Shield And Retainers
    G03900504Courtesy of FORD MOTOR CO.
  40. Install the RH splash shield and the 7 retainers.
    Fig 37: Locating Retainers & RH Splash Shield
    G04620611Courtesy of FORD MOTOR CO.
  41. Install the bolt for the RH engine mount.
    • Tighten to 115 N.m (85 lb-ft).
      Fig 38: Locating Bolt For RH Engine Mount
      G04620612Courtesy of FORD MOTOR CO.
  42. Tighten the LH upper transaxle mount assembly.
    1. Tighten the 4 nuts for the bracket.
      • Tighten to 40 N.m (30 lb-ft).
    2. Install the through bolt.
      • Tighten to 103 N.m (76 lb-ft).
        Fig 39: Locating LH Upper Transaxle Mount Assembly Bolt
        G04620613Courtesy of FORD MOTOR CO.
  43. Install the upper transaxle retaining bolts.
    • Tighten to 40 N.m (30 lb-ft).
      Fig 40: Locating Upper Transaxle Retaining Bolts
      G04620614Courtesy of FORD MOTOR CO.
  44. Remove the special tools.
    Fig 41: Identifying Special Tools (1 Of 3)
    G04620615Courtesy of FORD MOTOR CO.
  45. Remove the special tools.
    Fig 42: Identifying Special Tools (2 Of 3)
    G04620616Courtesy of FORD MOTOR CO.
  46. Remove the special tools.
    Fig 43: Identifying Special Tools (3 Of 3)
    G04620617Courtesy of FORD MOTOR CO.
  47. Connect the electrical connectors together and then connect them to the upper intake manifold.
    Fig 44: Locating Electrical Connectors
    G04620618Courtesy of FORD MOTOR CO.
  48. Install the starter motor and install the bolts.
    • Tighten to 25 N.m (18 lb-ft).
      Fig 45: Locating Starter Motor Bolts
      G04620619Courtesy of FORD MOTOR CO.
  49. Install the ground cable.
    • Tighten to 27 N.m (20 lb-ft).
      Fig 46: Locating Ground Cable
      G04620620Courtesy of FORD MOTOR CO.
  50. Install the starter motor harness connector.
    1. Install the large nut.
      • Tighten to 10 N.m (89 lb-in).
    2. Install the small nut.
      • Tighten to 7 N.m (62 lb-in).
        Fig 47: Locating Starter Motor Harness Connector & Nut
        G04620621Courtesy of FORD MOTOR CO.
  51. Install the shift cable and the bracket.
    • Tighten to 23 N.m (17 lb-ft).
      Fig 48: Locating Shift Cable & Bracket
      G04620622Courtesy of FORD MOTOR CO.
  52. Connect the shift cable to the manual lever.
    Fig 49: Locating Shift Cable End At Manual Lever
    G03897855Courtesy of FORD MOTOR CO.
  53. Connect the wire harness to the battery hold-down bracket.
    Fig 50: Locating Wire Harness Bracket
    G04620624Courtesy of FORD MOTOR CO.
  54. Connect the EVAP and PTO vent hose to the transmission filler tube bracket.
    Fig 51: Locating EVAP & Power Takeoff (PTO) Vent Hoses
    G04620625Courtesy of FORD MOTOR CO.
  55. Install the main control cover vent tube.
    Fig 52: Locating Main Control Cover Vent Tube
    G04620626Courtesy of FORD MOTOR CO.
  56. Position the bracket in place and install the nut. Connect the transaxle harness connector.
    • Tighten to 10 N.m (89 lb-in).
      Fig 53: Locating Transaxle Harness Connector & Nut
      G04620627Courtesy of FORD MOTOR CO.
  57. Connect the transmission range (TR) sensor.
    Fig 54: Locating Transmission Range (TR) Sensor Electrical Connector
    G03897857Courtesy of FORD MOTOR CO.
    58. NOTE: If installing an exchange transaxle, the digital TR sensor must be aligned.
  58. Using the special tool, align the digital TR sensor.
    • Tighten to 10 N.m (89 lb-in).
      Fig 55: Aligning Digital TR Sensor
      G04620629Courtesy of FORD MOTOR CO.
  59. 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 N.m (89 lb-in).
    4. Install the breather tube.
    5. Connect the mass air flow (MAF) sensor electrical connector.
      Fig 56: Identifying Air Cleaner Assembly
      G04620630Courtesy of FORD MOTOR CO.
    60. NOTE: Before installing the battery tray, check the vent tube hose for any obstructions, kinks or incorrect routing position.
  60. Install the battery tray. For additional information, refer to REMOVAL AND INSTALLATION .
  61. Fill the transaxle with clean automatic transmission fluid.
  62. Check the fluid level and correct as necessary.
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