Section 12 (Automatic Transmission - (Hybrid)): Installation: Transaxle

SPECIAL TOOL DESCRIPTION

	Heavy Duty Floor Crane 014-00071 or equivalent
	Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
	Powertrain Lift 014-00765
	Universal Adapter Brackets 014-0001 Lifting Bracket Set, Engine 303-D095 (D94L-6001-A) or equivalent

WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury.

WARNING: To prevent exposure to high voltage, do not for any reason open the electronically controlled, continuously variable transmission (eCVT) cover. Failure to follow these instructions may result in personal injury.

All vehicles 

CAUTION: The damper contains a clutch which designed to slip briefly during vehicle operation. It is essential that no grease, oil or cleaning solvents be allowed to contaminate the slip clutch. Do not use grease on transmission input shaft or input shaft splines.
Should the damper become contaminated it must be replaced.
NOTE: Due to packaging requirements, the correct bolt must be used at the damper locations.
1. Install the transaxle damper.
   • Tighten to 29 Nm (21 lb-ft).
     Fig 1: Installing Transaxle Damper

     Courtesy of FORD MOTOR CO.
CAUTION: When positioning the engine to the transaxle, care must be taken to maintain alignment of the damper spline with the transaxle input shaft.
NOTE: Transaxle removed from view for clarity.
2. Using the engine crane and spreader bar, position the engine and transaxle together. Install the 6 transaxle-to-engine bolts.
   • Tighten to 47 Nm (35 lb-ft).
     Fig 2: Installing Transaxle-To-Engine Bolts

     Courtesy of FORD MOTOR CO.
3. Position the wiring harness in place and install the wiring harness fasteners on the transaxle stud bolts.
   Fig 3: Installing Wiring Harness Fasteners On Transaxle Stud Bolts

   Courtesy of FORD MOTOR CO.
4. Connect the high voltage wiring harness electrical connector.
   Fig 4: Connecting High Voltage Wiring Harness Electrical Connector

   Courtesy of FORD MOTOR CO.
5. Using the engine crane and spreader bar, position the engine and transaxle onto the lift table.
CAUTION: Due to the weight of the transaxle, special care should be taken to mount the powertrain securely to the lift table.
Fig 5: Identifying Engine Lift Table
Courtesy of FORD MOTOR CO.
6. Using the special tools, secure the engine to the lift table.
7. Raise the engine and transaxle into the vehicle.
8. Install the rear transaxle mount.
   • Tighten to 90 Nm (66 lb-ft).
     Fig 6: Installing Rear Transaxle Mount

     Courtesy of FORD MOTOR CO.
9. Install the rear transaxle mount bracket.
   • Tighten to 25 Nm (18 lb-ft).
     Fig 7: Installing Rear Transaxle Mount Bracket

     Courtesy of FORD MOTOR CO.
10. Install the RH transaxle mount bracket.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 8: Installing RH Transaxle Mount Bracket

      Courtesy of FORD MOTOR CO.
11. Install the RH transaxle mount bracket nut.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 9: Installing RH Transaxle Mount Bracket Nut

      Courtesy of FORD MOTOR CO.
12. Install the engine mount bracket.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 10: Installing Engine Mount Bracket

      Courtesy of FORD MOTOR CO.
13. Install the engine mount bracket bolt.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 11: Installing Engine Mount Bracket Bolt

      Courtesy of FORD MOTOR CO.
14. Install the 2 transaxle-to-engine bolts.
    • Tighten to 47 Nm (35 lb-ft).
      Fig 12: Installing Transaxle-To-Engine Bolts

      Courtesy of FORD MOTOR CO.
15. Install the 2 transaxle-to-engine bolts.
    • Tighten to 47 Nm (35 lb-ft).
      Fig 13: Installing Transaxle-To-Engine Bolts

      Courtesy of FORD MOTOR CO.
16. Install the engine support crossmember nut and bolts.
    • Tighten to 175 Nm (129 lb-ft).
      Fig 14: Installing Engine Support Crossmember Nut And Bolts

      Courtesy of FORD MOTOR CO.
17. Position the roll restrictor bracket on the transaxle and install the rear roll restrictor bracket bolts.
    • Tighten to 55 Nm (41 lb-ft).
      Fig 15: Installing Rear Roll Restrictor Bracket Bolts

      Courtesy of FORD MOTOR CO.
18. Install the front roll restrictor bolt.
    • Tighten to 115 Nm (85 lb-ft).
      Fig 16: Installing Front Roll Restrictor Bolt

      Courtesy of FORD MOTOR CO.
19. Install the A/C compressor.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 17: Installing A/C Compressor

      Courtesy of FORD MOTOR CO.
20. Connect the lower radiator hose to the radiator.
    Fig 18: Locating Lower Radiator Hose At Radiator

    Courtesy of FORD MOTOR CO.
21. Install the motor electronics coolant pump.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 19: Installing Motor Electronics Coolant Pump

      Courtesy of FORD MOTOR CO.
22. Install the wiring harness fasteners, the ground cable and nut.
    • Tighten to 20 Nm (15 lb-ft).
      Fig 20: Installing Wiring Harness Fasteners, Ground Cable And Nut

      Courtesy of FORD MOTOR CO.
23. Connect the transaxle coolant hoses.
    Fig 21: Connecting Transaxle Coolant Hoses

    Courtesy of FORD MOTOR CO.
24. Connect the motor electronics coolant temperature sensor electrical connector and pin-type retainer.
    Fig 22: Connecting Motor Electronics Coolant Temperature Sensor Electrical Connector And Pin-Type Retainer

    Courtesy of FORD MOTOR CO.
25. Install the selector lever cable in the retainer.
    Fig 23: Installing Selector Lever Cable Retainer

    Courtesy of FORD MOTOR CO.
26. Connect the transaxle control cable.
    • Install the transaxle control cable bracket and the 2 nuts finger tight.
    • Attach the transaxle control cable to the control lever.
    • Tighten to 22 Nm (16 lb-ft).
      Fig 24: Installing Transaxle Control Cable Bracket And Nuts Finger Tight

      Courtesy of FORD MOTOR CO.
27. Position the control lever between the 2 casting ribs on the transaxle case.
    Fig 25: Positioning Control Lever Between Casting Ribs On Transaxle Case

    Courtesy of FORD MOTOR CO.
28. Place the selector lever in the D position.
29. Tighten the transaxle control cable bracket nuts to 22 Nm (16 lb-ft).
30. To verify the correct cable adjustment, observe the control lever on the transaxle while an assistant shifts the selector lever to each range position ending in the D position.
31. Install the transaxle control splash shield.
    • Tighten to 15 Nm (11 lb-ft).
      Fig 26: Locating Bolts And Transaxle Control Snow Shield

      Courtesy of FORD MOTOR CO.
32. Connect the steering gear electrical connector and wiring harness retainer.
    Fig 27: Connecting Steering Gear Electrical Connector And Wiring Harness Retainer

    Courtesy of FORD MOTOR CO.
33. Install the motor auxiliary coolant pump and connect the electrical connector.
    • Tighten to 10 Nm (89 lb-in).
      Fig 28: Installing Motor Auxiliary Coolant Pump And Connect Electrical Connector

      Courtesy of FORD MOTOR CO.
NOTE: Parts removed from view for clarity.
34. If equipped, install the block heater wiring harness.
    • Route the harness through the radiator support.
    • Attach the 3 harness retainer clips.
      Fig 29: Attaching Harness Retainer Clips

      Courtesy of FORD MOTOR CO.
35. Position the DC-to-DC converter in place and install the 3 nuts.
    • Tighten to 12 Nm (9 lb-ft).
      Fig 30: Positioning DC-To-DC Converter

      Courtesy of FORD MOTOR CO.
36. Connect the DC-to-DC converter electrical connector and the wiring harness retainers.
    Fig 31: Connecting DC-To-DC Converter Electrical Connector And Wiring Harness Retainers

    Courtesy of FORD MOTOR CO.
37. Connect the 2 low voltage electrical connectors and the engine harness-to-body harness retainer.
    Fig 32: Connecting Low Voltage Electrical Connectors And Engine Harness-To-Body Harness Retainer

    Courtesy of FORD MOTOR CO.
38. Connect the transaxle harness electrical connector and install the bolt.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 33: Connecting Transaxle Harness Electrical Connector

      Courtesy of FORD MOTOR CO.
39. Install the selector lever cable fasteners on the transaxle stud bolts.
    Fig 34: Installing Selector Lever Cable Fasteners On Transaxle Stud Bolts

    Courtesy of FORD MOTOR CO.
40. Connect the engine control harness electrical connector and the pin-type retainer.
    Fig 35: Connecting Engine Control Harness Electrical Connector And Pin-Type Retainer

    Courtesy of FORD MOTOR CO.
41. Install the ground strap on the PCM stud and install the nut.
    • Tighten to 6 Nm (53 lb-in).
      Fig 36: Installing Ground Strap On PCM Stud

      Courtesy of FORD MOTOR CO.
42. Connect the engine control harness.
    • Engage the powertrain control module (PCM) connector.
    • Install the harness retaining nut.
    • Tighten to 6 Nm (53 lb-in).
      Fig 37: Installing Harness Retaining Nut

      Courtesy of FORD MOTOR CO.
43. Connect the upper radiator and coolant vent hoses.
    Fig 38: Connecting Upper Radiator And Coolant Vent Hoses

    Courtesy of FORD MOTOR CO.
44. Attach the heater hose retaining clip to the transaxle mount stud.
    Fig 39: Attaching Heater Hose Retaining Clip To Transaxle Mount Stud

    Courtesy of FORD MOTOR CO.
45. Connect the heater hoses to the heater core.
    Fig 40: Locating Heater Hoses At Heater Core

    Courtesy of FORD MOTOR CO.

4WD vehicles 

46. Position the transfer case in place and install the 4 bolts.
    • Tighten to 45 Nm (33 lb-ft).
      Fig 41: Positioning Transfer Case In Place

      Courtesy of FORD MOTOR CO.
47. Connect the transfer case vent hose.
    Fig 42: Connecting Transfer Case Vent Hose

    Courtesy of FORD MOTOR CO.
48. Position the transfer case-to-engine support bracket and install the bolts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 43: Positioning Transfer Case-To-Engine Support Bracket

      Courtesy of FORD MOTOR CO.
49. Install the transfer case heat shield and the bolts.
    • Tighten to 14 Nm (10 lb-ft).
      Fig 44: Installing Transfer Case Heat Shield And Bolts

      Courtesy of FORD MOTOR CO.
50. Install the driveshaft. For additional information, refer to DRIVESHAFT .

All vehicles 

51. Install the lateral support crossmember and the 4 bolts.
    • Tighten to 115 Nm (85 lb-ft).
      Fig 45: Identifying Lateral Support Crossmember And Bolts

      Courtesy of FORD MOTOR CO.
52. Install the front drive intermediate halfshaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
53. Install the LH front drive halfshaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
54. Install the engine coolant degas bottle. For additional information, refer to ENGINE COOLING - HYBRID .
55. Install the catalytic converter. For additional information, refer to EXHAUST SYSTEM .
56. Install the intake manifold. For additional information, refer to ENGINE - HYBRID 2.3L .
57. Install the engine air cleaner. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - HYBRID .
58. Enable the vehicle high voltage electrical system. For additional information, refer to HIGH VOLTAGE TRACTION BATTERY .
59. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
60. Reset the passive anti-theft system (PATS). For additional information, refer to ANTI-THEFT - PATS .
61. Check and fill the transmission fluid level. For additional information, refer to TRANSMISSION FLUID DRAIN AND REFILL .
62. Fill and bleed the motor electronics cooling system. For additional information, refer to TRANSAXLE-TRANSMISSION COOLING - HYBRID .
63. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING - HYBRID .