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Transaxle - Front Wheel Drive (FWD): Installation

WARNING: This page is about a different car, the 2006 Mercury Montego, 2006 Ford Freestyle, and 2006 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION:
  1. MERCON®, MERCON® V, MERCON® SP, Motorcraft Premium Automatic Transmission Fluid and Motorcraft Continuously Variable Chain Type Transmission Fluid are not interchangeable transmission fluids. The use of any fluid other than what is recommended for this transaxle will cause transaxle damage.
  2. If a new transaxle or a mechatronic main control valve body assembly is installed, the transmission control module (TCM) will need to be reflashed to the latest level calibration available. If the TCM is not reflashed, the wrench light on the dash may illuminate and internal transaxle damage may occur.
NOTE: If the transaxle was overhauled, or if installing a new transaxle and the transmission fluid cooler tubes have not been flushed, flush the transmission fluid cooler tubes at this time. For additional information, refer to TRANSMISSION FLUID COOLER TUBES - BACKFLUSHING AND CLEANING .

If the transaxle was overhauled or if installing a new transaxle and a new transmission fluid cooler has not been installed, install a new transmission fluid cooler at this time. For additional information, refer to REMOVAL AND INSTALLATION .

  1. If installing a new transaxle, install the transmission fluid level indicator, tube and the bolt.
    • Tighten to 10 N.m (89 lb-in).
    Fig 1: Locating Transmission Fluid Level Indicator, Tube & Bolt
    G04657107Courtesy of FORD MOTOR CO.
  2. If installing a new transaxle, install the transaxle insulator using new retainers.
    Fig 2: Locating Transaxle Insulator Retainers
    G04657108Courtesy of FORD MOTOR CO.
  3. If removed, clean the rear transaxle mount bolts using a wire brush and apply new threadlock to the threads.
  4. If installing a new transaxle, install the rear transaxle support insulator.
    • Tighten to 55 N.m (41 lb-ft).
    Fig 3: Locating Rear Transaxle Support Insulator Bolts
    G04657109Courtesy of FORD MOTOR CO.
  5. Prior to installing the original or a new transaxle, apply multi-purpose grease to the torque converter pilot hub.
    Fig 4: Locating Torque Converter Pilot Hub
    G04657110Courtesy of FORD MOTOR CO.
  6. Position the transaxle to the back of the engine.
  7. Install the 3 transaxle-to-engine retaining bolts.
    • Tighten to 40 N.m (30 lb-ft).
    Fig 5: Locating Transaxle-To-Engine Retaining Bolts
    G04657111Courtesy of FORD MOTOR CO.
  8. Install 4 new transmission fluid cooler tube seals.
    Fig 6: Locating Transmission Fluid Cooler Tube Seals
    G04657112Courtesy of FORD MOTOR CO.
    9. CAUTION: Make sure that when installing the transmission fluid cooler tubes they are installed straight, or damage to the tubes will occur.
    Fig 7: Locating Transmission Fluid Cooler Tubes
    G04657113Courtesy of FORD MOTOR CO.
  9. Connect the transmission fluid cooler tubes to the transaxle.
    • Tighten to 10 N.m (89 lb-in).
  10. Position the transmission fluid cooler tubes in place and install the bolts.
    • Tighten to 10 N.m (89 lb-in).
    Fig 8: Locating Transmission Fluid Cooler Tubes Bolts
    G04657114Courtesy of FORD MOTOR CO.
  11. Install 4 new torque converter retaining nuts.
    • Tighten to 36 N.m (27 lb-ft).
    Fig 9: Locating Torque Converter Retaining Nut
    G04657115Courtesy of FORD MOTOR CO.
  12. Install the lower rubber access plug and install the retaining pin.
    Fig 10: Locating Lower Rubber Access Plug
    G04657116Courtesy of FORD MOTOR CO.
  13. Position the catalytic converter in place and loosely install the bolt for the bracket.
    Fig 11: Locating Bracket Bolt
    G04657117Courtesy of FORD MOTOR CO.
  14. Connect the heated oxygen sensor (HO2S) electrical connector.
    Fig 12: Locating Heated Oxygen Sensor (HO2S) Electrical Connector
    G04657118Courtesy of FORD MOTOR CO.
  15. Using a suitable powertrain lift, position the subframe in place and install the 4 bolts.
    • Tighten to 90 N.m (66 lb-ft).
    Fig 13: Locating Subframe Bolts
    G04657119Courtesy of FORD MOTOR CO.
  16. Install the 2 bolts for the LH rear subframe mount.
    • Tighten to 48 N.m (35 lb-ft).
    Fig 14: Locating LH Rear Subframe Mount Bolts
    G04657120Courtesy of FORD MOTOR CO.
  17. Install the 2 bolts for the RH rear subframe mount.
    • Tighten to 48 N.m (35 lb-ft).
    Fig 15: Locating RH Rear Subframe Mount Bolts
    G04657121Courtesy of FORD MOTOR CO.
  18. Install the 2 bolts for the rear transaxle mount.
    • Tighten to 90 N.m (66 lb-ft).
    Fig 16: Locating Rear Transaxle Mount Bolts
    G04657122Courtesy of FORD MOTOR CO.
  19. Install the nut for the rear motor mount.
    • Tighten to 70 N.m (52 lb-ft).
    Fig 17: Locating Rear Motor Mount Nut
    G04657123Courtesy of FORD MOTOR CO.
  20. Install the 2 bolts for the lower stabilizer mount.
    • Tighten to 70 N.m (52 lb-ft).
    Fig 18: Locating Lower Stabilizer Mount Bolts
    G04657124Courtesy of FORD MOTOR CO.
  21. Install the nut for the front motor mount.
    • Tighten to 70 N.m (52 lb-ft).
    Fig 19: Locating Front Motor Mount Nut
    G04657125Courtesy of FORD MOTOR CO.
  22. Position the splash shield in place and install the 3 pushpins.
    Fig 20: Locating Splash Shield Pushpins
    G04657126Courtesy of FORD MOTOR CO.
  23. Connect the HO2S electrical connector to the subframe.
    Fig 21: Locating HO2S Electrical Connector
    G04657127Courtesy of FORD MOTOR CO.
  24. Position the power steering rack in place. Install the bolts and nuts.
    • Tighten to 133 N.m (98 lb-ft).
    Fig 22: Locating Power Steering Rack Bolt & Nut
    G04657128Courtesy of FORD MOTOR CO.
  25. Position the power steering line in place and install the 4 bolts.
    • Tighten to 7 N.m (62 lb-in).
    Fig 23: Locating Power Steering Line Bolt
    G04657129Courtesy of FORD MOTOR CO.
  26. Connect the wire harness to the LH front subframe.
    Fig 24: Locating Wire Harness
    G04657130Courtesy of FORD MOTOR CO.
  27. Position the lower radiator hose in place and connect the retainers.
    Fig 25: Locating Lower Radiator Hose
    G04657131Courtesy of FORD MOTOR CO.
  28. Install the LH and RH stabilizer bar link into the struts and install new nuts.
    • Tighten to 55 N.m (41 lb-ft).
    Fig 26: Locating Stabilizer Bar Link Nut
    G04657132Courtesy of FORD MOTOR CO.
  29. Remove the special tool from the lifting hook near the exhaust gas recirculation (EGR) valve.
    Fig 27: Identifying Special Tools (303-1140, 303-290A-12)
    G04657133Courtesy of FORD MOTOR CO.
  30. Remove the special tools from the RH (rear) cylinder head.
    Fig 28: Identifying Special Tools (134-00243, 303-290A-12)
    G04657134Courtesy of FORD MOTOR CO.
  31. Remove the special tools from the LH (front) cylinder head.
    Fig 29: Identifying Special Tools (134-00243, 303-290A-12)
    G04657135Courtesy of FORD MOTOR CO.
  32. Remove the special tools.
    Fig 30: Identifying Special Tools (303-290-01, 303-290A, 303-290A-03A, 303-290A-12)
    G04657136Courtesy of FORD MOTOR CO.
  33. Install new bolts for the catalytic converter.
    • Tighten to 40 N.m (30 lb-ft).
    Fig 31: Locating Catalytic Converter Bolts
    G04657137Courtesy of FORD MOTOR CO.
  34. Remove the upper half of the lifting hook.
    Fig 32: Identifying Special Tool (303-1140)
    G04657138Courtesy of FORD MOTOR CO.
  35. Remove the lower half of the lifting hook.
    Fig 33: Locating Lower Half Of Lifting Hook On Special Tool (303-1140)
    G04657139Courtesy of FORD MOTOR CO.
  36. Install the transaxle-to-engine bolt.
    • Tighten to 40 N.m (30 lb-ft).
    Fig 34: Locating Transaxle-To-Engine Bolt
    G04657140Courtesy of FORD MOTOR CO.
  37. Connect the knock sensor wire harness to the transaxle.
    Fig 35: Locating Knock Sensor Wire Harness
    G04657141Courtesy of FORD MOTOR CO.
  38. Install the knock sensor.
    • Tighten to 10 N.m (89 lb-in).
    Fig 36: Locating Knock Sensor Bolt
    G04657142Courtesy of FORD MOTOR CO.
  39. Install the heat shield over the knock sensor.
    Fig 37: Locating Heat Shield
    G04657143Courtesy of FORD MOTOR CO.
  40. If equipped, connect the engine block heater.
    Fig 38: Locating Engine Block Heater
    G04657144Courtesy of FORD MOTOR CO.
  41. Position the power steering hose in place and install the bolt.
    • Tighten to 7 N.m (62 lb-in).
    Fig 39: Locating Power Steering Hose Bolt
    G04657145Courtesy of FORD MOTOR CO.
  42. Tighten the catalytic converter bolt to the bracket.
    • Tighten to 40 N.m (30 lb-ft).
    Fig 40: Locating Catalytic Converter Bolt
    G04657146Courtesy of FORD MOTOR CO.
  43. Install the LH and RH half shafts. For additional information, refer to INSTALLATION and INSTALLATION .
  44. Position the exhaust crossover pipe and install 2 new bolts for the catalytic converter and connect the rubber hanger.
    • Tighten to 40 N.m (30 lb-ft).
    Fig 41: Locating Catalytic Converter Bolts
    G04657147Courtesy of FORD MOTOR CO.
  45. Install 2 new nuts for the rear exhaust pipe.
    • Tighten to 40 N.m (30 lb-ft).
    Fig 42: Locating Rear Exhaust Pipe Nuts
    G04657148Courtesy of FORD MOTOR CO.
  46. Install 2 new nuts for the front exhaust pipe.
    • Tighten to 40 N.m (30 lb-ft).
    Fig 43: Locating Front Exhaust Pipe Nuts
    G04657149Courtesy of FORD MOTOR CO.
  47. Install the 4 upper transaxle bolts.
    • Tighten to 40 N.m (30 lb-ft).
    Fig 44: Locating Upper Transaxle Bolts
    G04657150Courtesy of FORD MOTOR CO.
  48. Install the bolt for the power steering line.
    • Tighten to 7 N.m (62 lb-in).
    Fig 45: Locating Power Steering Line Bolt
    G04657151Courtesy of FORD MOTOR CO.
  49. Connect the vapor tube to the canister purge valve.
    Fig 46: Locating Canister Purge Valve
    G04657152Courtesy of FORD MOTOR CO.
  50. Install the positive crankcase ventilation (PCV) hose.
    Fig 47: Locating Positive Crankcase Ventilation (PCV) Hose
    G04657153Courtesy of FORD MOTOR CO.
  51. Connect the vacuum hose to the throttle body.
    Fig 48: Locating Vacuum Hose
    G04657154Courtesy of FORD MOTOR CO.
  52. Position the bracket for the power steering hose and install the bolt.
    • Tighten to 7 N.m (62 lb-in).
    Fig 49: Locating Power Steering Hose Bracket Bolt
    G04657155Courtesy of FORD MOTOR CO.
  53. Install the transmission fluid cooler tube bracket to the transaxle.
    • Tighten to 10 N.m (89 lb-in).
    Fig 50: Locating Transmission Fluid Cooler Tube Bracket Bolt
    G04657156Courtesy of FORD MOTOR CO.
  54. Connect the ground wire.
    • Tighten to 12 N.m (9 lb-ft).
    Fig 51: Locating Ground Wire
    G04657157Courtesy of FORD MOTOR CO.
  55. Connect the wire harness to the transaxle.
    Fig 52: Locating Wire Harness
    G04657158Courtesy of FORD MOTOR CO.
    56. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
    Fig 53: Locating Transaxle Bulkhead Electrical Connector
    G04657159Courtesy of FORD MOTOR CO.
  56. Connect the transaxle bulkhead electrical connector.
  57. Install the starter motor.
    • Tighten to 26 N.m (19 lb-ft).
    Fig 54: Locating Starter Motor Bolts
    G04657160Courtesy of FORD MOTOR CO.
  58. Connect the 2 starter motor electrical connectors.
    • Tighten the larger nut to 12 N.m (9 lb-ft).
    • Tighten the smaller nut to 5 N.m (44 lb-in).
    Fig 55: Locating Starter Motor Electrical Connectors
    G04657161Courtesy of FORD MOTOR CO.
  59. Install the electrical cover for the starter motor electrical connectors.
    Fig 56: Locating Starter Motor Electrical Connectors
    G04657162Courtesy of FORD MOTOR CO.
  60. Clean the roll restrictor bolts using a wire brush and apply new threadlock to the threads.
  61. Position the roll restrictor in place, install the bolts and connect the wire harness to the roll restrictor.
    • Tighten to 40 N.m (30 lb-ft).
    Fig 57: Locating Roll Restrictor
    G04657163Courtesy of FORD MOTOR CO.
  62. Clean the 4 roll restrictor bracket bolts using a wire brush and apply new threadlock to the threads.
  63. Install the roll restrictor bracket and 4 bolts.
    • Tighten to 40 N.m (30 lb-ft).
    Fig 58: Locating Roll Restrictor Bracket Bolts
    G04657164Courtesy of FORD MOTOR CO.
  64. Connect the lower wire harness to the transaxle.
    Fig 59: Locating Lower Wire Harness
    G04657165Courtesy of FORD MOTOR CO.
  65. If equipped, install the auxiliary coolant flow pump assembly.
    1. Tighten to 7 N.m (62 lb-in).
    2. Install the electrical connector.
    Fig 60: Identifying Auxiliary Coolant Flow Pump Assembly
    G04657166Courtesy of FORD MOTOR CO.
  66. Connect the wire harness to the transaxle.
    Fig 61: Locating Wire Harness
    G04657167Courtesy of FORD MOTOR CO.
  67. Install the shift cable bracket and bolts.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 62: Locating Shift Cable Bracket Bolts
    G04657168Courtesy of FORD MOTOR CO.
  68. Connect the electrical connector to the shift cable bracket.
    Fig 63: Locating Electrical Connector
    G04657169Courtesy of FORD MOTOR CO.
  69. Connect the shift cable end.
    Fig 64: Locating Shift Cable End
    G04657170Courtesy of FORD MOTOR CO.
  70. Clean the 4 roll restrictor brace bolts using a wire brush and apply new threadlock to the threads.
  71. Position the roll restrictor brace in place and install the 4 bolts.
    • Tighten to 40 N.m (30 lb-ft).
    Fig 65: Locating Roll Restrictor Brace Bolts
    G04657171Courtesy of FORD MOTOR CO.
  72. Clean the upper roll restrictor bolt using a wire brush and apply new threadlock to the threads.
  73. Install the upper roll restrictor bolt.
    • Tighten to 48 N.m (35 lb-ft).
    Fig 66: Locating Upper Roll Restrictor Bolt
    G04657172Courtesy of FORD MOTOR CO.
  74. Install the cowl panel grille. For additional information, refer to REMOVAL AND INSTALLATION .
  75. Install the air cleaner and outlet tube. For additional information, refer to REMOVAL AND INSTALLATION .
  76. Install the battery tray and the battery. For additional information, refer to REMOVAL AND INSTALLATION .
  77. If required, fill the transaxle with clean continuously variable transaxle (CVT) transmission fluid. Use the transmission fluid level setting procedure to fill the transaxle. For additional information, refer to TRANSMISSION FLUID LEVEL CHECK AND SETTING .
  78. If a new transaxle or a mechatronic main control valve body assembly is installed, the TCM will need to be reflashed to the latest level calibration available. If the TCM is not reflashed, the wrench light on the dash may illuminate and internal transaxle damage may occur.
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