Transaxle - 2.5L: Removal

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.

NOTE: Carry out transmission fluid cooler backflushing and cleaning if the transaxle is being overhauled or if installing a new or remanufactured transaxle. For additional information, refer to TRANSMISSION FLUID COOLER BACKFLUSHING AND CLEANING .

NOTE: Carry out the transmission fluid cooler flow test if the transaxle is being overhauled or if installing a new or remanufactured transaxle. For additional information, refer to TRANSMISSION FLUID COOLER .

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING -- ESCAPE, ESCAPE HYBRID, MARINER & MARINER HYBRID .
Remove the battery and the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
Remove the Air Cleaner (ACL) and outlet pipe assembly. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING - 2.5L .
All-Wheel Drive (AWD) vehicles
Disconnect the Power Transfer Unit (PTU) vent hose from the clip located on the transaxle filler tube.

Fig 1: Locating Power Transfer Unit (PTU) Vent Hose
Courtesy of FORD MOTOR CO.

All vehicles
Disconnect the selector lever cable from the manual control lever.

Fig 2: Disconnecting Selector Lever Cable End From Manual Control Lever
Courtesy of FORD MOTOR CO.
Remove the 2 retaining bolts and position the selector lever cable and bracket aside.

Fig 3: Locating Selector Lever Cable Bracket Retaining Bolts
Courtesy of FORD MOTOR CO.
Remove the selector lever cable retainer from the transaxle filler tube bracket.

Fig 4: Locating Selector Lever Cable Retainer
Courtesy of FORD MOTOR CO.

NOTE: Transaxle removed for clarity.

Fig 5: Locating Upper Transaxle Retaining Bolts

Courtesy of FORD MOTOR CO.

Remove the 3 upper transaxle retaining bolts.
Install the Engine Support Bar and Adapters and support the engine and transaxle.

Fig 6: Identifying Special Tools (303-290A-01), (303-290A) And (303-290A-03A)
Courtesy of FORD MOTOR CO.
Remove the LH support insulator through bolt.

Fig 7: Locating LH Support Insulator Through Bolt
Courtesy of FORD MOTOR CO.
Remove the 4 nuts and the support insulator bracket.

Fig 8: Locating Support Insulator Bracket Nuts
Courtesy of FORD MOTOR CO.
Remove the front wheels and tires. For additional information, refer to WHEELS & TIRES .
Remove the 7 retainers and the LH splash shield.

Fig 9: Locating LH Splash Shield Retainer
Courtesy of FORD MOTOR CO.
Remove the starter motor. For additional information, refer to STARTING SYSTEM .
Remove the LH front halfshaft and RH intermediate shaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .

NOTE: AWD shown, FWD similar. Vehicles equipped with AWD have a damper that is held on by the through bolt.

Remove the lower support insulator.
1. Remove the lower support insulator through bolt.
2. Remove the lower support insulator bolt and 2 nuts.
3. Remove the lower support insulator.
  
  Fig 10: Identifying Lower Support Insulator Through Bolt, Lower Support Insulator Bolt And Lower Support Insulator
  Courtesy of FORD MOTOR CO.
AWD vehicles
Index the driveshaft to the yoke and remove the 6 bolts holding the driveshaft to the PTU and position aside.

Fig 11: Locating Driveshaft Bolts
Courtesy of FORD MOTOR CO.

All vehicles
Remove the 4 bolts and remove the cross brace.

Fig 12: Locating Rear Cross Brace Bolts
Courtesy of FORD MOTOR CO.
Remove the lower front support insulator through bolt for the mount and the 2 bolts from the cross brace.

Fig 13: Locating Lower Front Insulator Through Bolt And Cross Brace Bolts
Courtesy of FORD MOTOR CO.
Remove and discard the nut and remove the rear cross brace.

Fig 14: Locating Cross Brace Nut And Brace
Courtesy of FORD MOTOR CO.

NOTE: If transmission disassembly or installation of a new transmission is necessary, the transmission fluid will need to be drained.

Fig 15: Locating Transmission Fluid Drain Plug

Courtesy of FORD MOTOR CO.

Remove the drain plug and drain the transmission fluid.
Install the transmission fluid drain plug.
- Tighten to 12 Nm (106 lb-in).
  
  Fig 16: Locating Transmission Fluid Drain Plug
  Courtesy of FORD MOTOR CO.
AWD vehicles
Remove the 2 exhaust bracket-to-intermediate shaft bracket bolts.

Fig 17: Locating Exhaust Bracket-To-Intermediate Shaft Bracket Bolts
Courtesy of FORD MOTOR CO.

NOTE: Exhaust removed for clarity.

Fig 18: Locating PTU Bracket-To-Engine Bolts

Courtesy of FORD MOTOR CO.

Remove the 4 PTU bracket-to-engine bolts.
Remove the PTU bracket-to-engine bolt.

Fig 19: Locating PTU Bracket-To-Engine Bolt
Courtesy of FORD MOTOR CO.
Remove the 2 PTU bracket-to- PTU bolts and remove the bracket.

Fig 20: Locating PTU Bracket-To-PTU Bolts And Bracket
Courtesy of FORD MOTOR CO.

NOTE: Exhaust removed for clarity.

Fig 21: Locating PTU Bolts

Courtesy of FORD MOTOR CO.

Remove the bolts from the PTU .
Remove the bolt and remove the PTU .

Fig 22: Locating PTU And Bolt
Courtesy of FORD MOTOR CO.

Front Wheel Drive (FWD) vehicles
Remove the 3 bolts and the dampener.

Fig 23: Locating Dampener Bolts
Courtesy of FORD MOTOR CO.

All vehicles
Remove the 3 bolts holding the transaxle front mount bracket.

Fig 24: Locating Transaxle Front Mount Bracket Bolts
Courtesy of FORD MOTOR CO.
Remove the 2 transmission fluid cooler tube secondary latches from the transmission fluid cooler tubes.

Fig 25: Locating Transmission Fluid Cooler Tube Secondary Latches
Courtesy of FORD MOTOR CO.
Using the Transmission Cooler Line Disconnect Tool, disconnect the 2 transmission fluid cooler tubes (1 shown).

Fig 26: Identifying Special Tool (307-569) On Transmission Fluid Cooler Tubes
Courtesy of FORD MOTOR CO.
Disconnect the transaxle vehicle harness electrical connector.

Fig 27: Locating Transaxle Vehicle Harness Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the Turbine Shaft Speed (TSS) sensor electrical connector.

Fig 28: Locating Turbine Shaft Speed (TSS) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the transaxle electrical wiring harness retainers from the transmission fluid pan stud bolts.

Fig 29: Locating Transaxle Electrical Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
Remove the starter motor isolator.

Fig 30: Locating Starter Motor Isolator
Courtesy of FORD MOTOR CO.
Remove and discard the 4 torque converter nuts.

Fig 31: Locating Torque Converter Nuts
Courtesy of FORD MOTOR CO.
Using the Engine Support Bar, lower the transmission.

Fig 32: Identifying Engine Support Bar (303-290A) On Transmission
Courtesy of FORD MOTOR CO.
Push the torque converter back from the flexplate. Use a suitable transmission jack to support the transaxle and remove the 3 rear bellhousing bolts.

Fig 33: Locating Rear Bellhousing Bolts
Courtesy of FORD MOTOR CO.
Remove the 4 remaining transaxle-to-engine bolts.

Fig 34: Locating Transaxle-To-Engine Bolts
Courtesy of FORD MOTOR CO.

NOTE: The torque converter is heavy. Install the Torque Converter Retainer before lowering the transaxle.

Fig 35: Identifying Special Tool (307-346)

Courtesy of FORD MOTOR CO.

Move the transaxle back far enough to install the Torque Converter Retainer.
Lower the transaxle from the engine compartment.

Fig 36: Identifying Transaxle
Courtesy of FORD MOTOR CO.