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Transaxle - 2.3L: 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.

    All vehicles 

  1. Lubricate the torque converter pilot hub with grease.
    Fig 1: Locating Torque Converter Pilot Hub
    G04620523Courtesy of FORD MOTOR CO.
  2. Rotate the torque converter to place the paint dot in the 6 o'clock position.
  3. Install the special tool.
    Fig 2: Identifying Special Tool
    G03900854Courtesy of FORD MOTOR CO.
  4. Position the transaxle in place.
    Fig 3: Identifying Positioning Transaxle In Place
    G04620525Courtesy of FORD MOTOR CO.
  5. Once the transaxle is in place, prior to bolting it to the engine, remove the special tool.
    Fig 4: Identifying Special Tool
    G03900854Courtesy of FORD MOTOR CO.
  6. Move the transaxle assembly toward the engine assembly and install the 4 bolts.
    • Tighten to 40 N.m (30 lb-ft).
      Fig 5: Locating Transaxle Assembly Bolts
      G04620527Courtesy of FORD MOTOR CO.
  7. Install the transaxle retaining bolts.
    • Tighten to 40 N.m (30 lb-ft).
      Fig 6: Locating Transaxle Retaining Bolts
      G04620528Courtesy of FORD MOTOR CO.
  8. Install 4 new torque converter nuts.
    • Tighten to 40 N.m (30 lb-ft).
      Fig 7: Locating Torque Converter Nut
      G03897896Courtesy of FORD MOTOR CO.
  9. Install the transmission fluid cooler tube.
    • Tighten to 23 N.m (17 lb-ft).
      Fig 8: Locating Transmission Fluid Cooler Tube
      G03897859Courtesy of FORD MOTOR CO.
  10. Install the output shaft speed (OSS) sensor.
    • Tighten to 12 N.m (9 lb-ft).
      Fig 9: Locating OSS Sensor Bolt
      G03897862Courtesy of FORD MOTOR CO.
  11. Install the fluid cooler tube.
    1. Connect the OSS sensor.
    2. Connect the turbine shaft speed (TSS) sensor (white connector).
      • Connect the wiring harness retainer to the transmission case.
    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 10: Identifying Fluid Cooler Tube & Bolt
        G04620532Courtesy of FORD MOTOR CO.
  12. Install the starter motor isolator.
    Fig 11: Identifying Starter Motor Isolator
    G03897895Courtesy of FORD MOTOR CO.
  13. Install the starter motor.
    • Tighten to 35 N.m (26 lb-ft).
      Fig 12: Locating Starter Motor Bolts
      G04620534Courtesy of FORD MOTOR CO.
  14. Install the starter terminals.
    1. Install the battery cable nut.
      • Tighten to 12 N.m (9 lb-ft).
    2. Install the starter solenoid terminal nut.
      • Tighten to 5 N.m (44 lb-in).
        Fig 13: Identifying Battery Cable & Starter Solenoid Terminal Nut
        G04620535Courtesy of FORD MOTOR CO.
  15. Install the wire harness clip retainer and the ground wire to starter bolts.
    • Tighten to 27 N.m (20 lb-ft).
      Fig 14: Locating Wire Harness Clip Retainer & Bolts
      G04620536Courtesy of FORD MOTOR CO.
  16. Install the lower front mount bracket.
    • Tighten to 80 N.m (59 lb-ft).
      Fig 15: Locating Lower Front Mount Bracket Bolts
      G04620537Courtesy of FORD MOTOR CO.
  17. Using the special tools, raise the transaxle.
    Fig 16: Raising Transaxle Using Special Tools
    G04620538Courtesy of FORD MOTOR CO.
  18. Install the LH upper transaxle mount through bolt.
    • Tighten to 103 N.m (76 lb-ft).
      Fig 17: Locating LH Transaxle Mount Through Bolt
      G04620539Courtesy of FORD MOTOR CO.
  19. Remove the special tools.
    Fig 18: Removing Special Tools (1 Of 2)
    G04620540Courtesy of FORD MOTOR CO.
  20. Remove the special tools.
    Fig 19: Removing Special Tools (2 Of 2)
    G04620541Courtesy of FORD MOTOR CO.
  21. Install the upper transaxle bolts.
    • Tighten to 40 N.m (30 lb-ft).
      Fig 20: Locating Upper Transaxle Bolts
      G04620542Courtesy of FORD MOTOR CO.
  22. Connect the transmission range (TR) sensor electrical connector.
    Fig 21: Locating Transmission Range (TR) Sensor Electrical Connector
    G03897857Courtesy of FORD MOTOR CO.
  23. Connect the shift cable to the manual lever and install the 2 bolts.
    • Tighten to 23 N.m (17 lb-ft).
      Fig 22: Locating Shift Cable Manual Lever Bolts
      G04620544Courtesy of FORD MOTOR CO.
  24. Install the wire harness bracket nut and plug in the bulkhead electrical connector.
    • Tighten to 10 N.m (89 lb-in).
      Fig 23: Locating Wire Harness Bracket Nut & Plug
      G04620545Courtesy of FORD MOTOR CO.
  25. Install the rear transmission mount.
    • Tighten to 90 N.m (66 lb-ft) (vehicles built through 10/2005).
    • Tighten to 80 N.m (59 lb-ft) (vehicles built after 10/2005).
      Fig 24: Locating Rear Transmission Mount Bolts
      G04620546Courtesy of FORD MOTOR CO.
  26. Install the rear transaxle mount through bolt.
    • Tighten to 115 N.m (85 lb-ft).
      Fig 25: Locating Rear Transaxle Mount Bolt
      G04620547Courtesy of FORD MOTOR CO.

    27. 4x2 vehicles 

  27. Install the dampener.
    1. Tighten to 70 N.m (52 lb-ft).
    2. Tighten to 48 N.m (35 lb-ft).
      Fig 26: Identifying Dampener
      G04620548Courtesy of FORD MOTOR CO.

    28. 4x4 vehicles 

  28. Install the power take-off (PTO) assembly.
    • Tighten to 45 N.m (33 lb-ft).
      Fig 27: Locating PTO Bolts
      G04620549Courtesy of FORD MOTOR CO.
  29. Position the driveshaft in place and install the nuts.
    • Tighten to 48 N.m (35 lb-ft).
      Fig 28: Locating Driveshaft Bolts
      G04620550Courtesy of FORD MOTOR CO.
  30. Install the driveshaft.
    • Tighten to 20 N.m (15 lb-ft).
      Fig 29: Locating Driveshaft Bolts
      G04620551Courtesy of FORD MOTOR CO.

    31. All vehicles 

  31. Install the bracket.
    • Tighten to 55 N.m (41 lb-ft).
      Fig 30: Locating Engine Mounting Bracket Bolts
      G04620552Courtesy of FORD MOTOR CO.
  32. Install the front nuts on the exhaust-to-intermediate shaft bracket.
    • Tighten to 30 N.m (22 lb-ft).
      Fig 31: Locating Exhaust-To-Intermediate Shaft Bracket Nuts
      G04620553Courtesy of FORD MOTOR CO.
  33. Install the bolts on the rear of the exhaust-to-intermediate shaft bracket.
    • Tighten to 30 N.m (22 lb-ft).
      Fig 32: Locating Bolts On Rear Of Exhaust-To-Intermediate Shaft Bracket
      G04620554Courtesy of FORD MOTOR CO.
  34. Install the flexpipe on the exhaust manifold and install the nuts.
    • Tighten to 25 N.m (18 lb-ft).
      Fig 33: Locating Flexpipe On Exhaust Manifold & Nuts
      G04620555Courtesy of FORD MOTOR CO.
  35. Install the intermediate shaft.
    Fig 34: Locating Intermediate Shaft
    G04620556Courtesy of FORD MOTOR CO.
  36. Install the intermediate shaft retaining nuts.
    • Tighten to 27 N.m (20 lb-ft).
      Fig 35: Locating Intermediate Shaft Retaining Nuts
      G04620557Courtesy of FORD MOTOR CO.
  37. Install the LH and RH halfshafts and frame bolts.
    • Tighten to 115 N.m (85 lb-ft).
      Fig 36: Locating LH, RH Halfshafts & Frame Bolts
      G04620558Courtesy of FORD MOTOR CO.
  38. Using the special tool, install the LH half shaft into the wheel knuckle.
    Fig 37: Installing LH Half Shaft Into Wheel Knuckle Using Special Tools
    G04620559Courtesy of FORD MOTOR CO.
  39. Install the LH hub nut.
    • Tighten to 290 N.m (214 lb-ft).
      Fig 38: Locating LH Hub Nut
      G04620560Courtesy of FORD MOTOR CO.
  40. 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 39: Identifying Cross Brace And Rear Nut
      G03897887Courtesy of FORD MOTOR CO.
  41. Install the 2 bolts for the brace.
    • Tighten to 90 N.m (66 lb-ft).
      Fig 40: Locating Bolts For Brace
      G04620562Courtesy of FORD MOTOR CO.
  42. Install the bolt for the mount.
    • Tighten to 115 N.m (85 lb-ft).
      Fig 41: Locating Bolt For Mount
      G04620563Courtesy of FORD MOTOR CO.
  43. Install the cross brace and the 4 bolts.
    • Tighten to 115 N.m (85 lb-ft).
      Fig 42: Locating Cross Brace & Bolts
      G03900713Courtesy of FORD MOTOR CO.
  44. Install the LH splash shield and the 7 retainers.
    Fig 43: View Of LH Splash Shield And Retainers
    G03900504Courtesy of FORD MOTOR CO.
  45. Install the RH splash shield and the 5 retainers.
    Fig 44: Locating RH Splash Shield & Retainers
    G04620566Courtesy of FORD MOTOR CO.

    46. 4x4 vehicles 

  46. Install the vent tube to the fluid level indicator.
    Fig 45: Locating Power Take-Off (PTO) Vent Hose
    G04620567Courtesy of FORD MOTOR CO.

    47. All vehicles 

  47. Install the air cleaner assembly.
    1. Install the bolt.
      • Tighten to 10 N.m (89 lb-in).
    2. Connect the mass air flow (MAF) sensor.
    3. Connect the brake booster vacuum hose.
    4. Connect the wiring harness retainer.
    5. Connect the breather tube.
    6. Tighten the air cleaner clamp.
      Fig 46: Identifying Air Cleaner Assembly Components
      G04620568Courtesy of FORD MOTOR CO.
  48. Install the battery tray. For additional information, refer to REMOVAL AND INSTALLATION .
  49. Fill the transaxle with clean automatic transmission fluid.
  50. Check the fluid level and correct as necessary.
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