Transaxle - 2.5L: Installation

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.

All vehicles

NOTE: Carry out the 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 .

Position the transaxle into the engine compartment.

Fig 1: Identifying Transaxle
Courtesy of FORD MOTOR CO.
Remove the Torque Converter Retainer.

Fig 2: Identifying Special Tool (307-346)
Courtesy of FORD MOTOR CO.
Lubricate the torque converter pilot hub with grease.

Fig 3: Locating Torque Converter Pilot Hub
Courtesy of FORD MOTOR CO.
Install the 4 torque converter housing bolts.
- Tighten to 48 Nm (35 lb-ft).
  
  Fig 4: Locating Transaxle-To-Engine Bolts
  Courtesy of FORD MOTOR CO.
Install the 3 torque converter housing bolts.
- Tighten to 48 Nm (35 lb-ft).
  
  Fig 5: Locating Rear Bellhousing Bolts
  Courtesy of FORD MOTOR CO.
Position the transaxle support insulator bracket in place and install the 4 nuts.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 6: Locating Support Insulator Bracket Nuts
  Courtesy of FORD MOTOR CO.
Using the Engine Support Bar and Adapters, raise the transaxle until the transaxle support insulator bracket lines up with the transaxle support insulator and install the through bolt.
- Tighten to 103 Nm (76 lb-ft).
  
  Fig 7: Identifying Engine Support Bar And Adapters
  Courtesy of FORD MOTOR CO.
Remove the Engine Support Bar and Adapters.

Fig 8: Identifying Special Tools (303-290A-01), (303-290A) And (303-290A-03A)
Courtesy of FORD MOTOR CO.
Install the 4 new torque converter nuts.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 9: Locating Torque Converter Nuts
  Courtesy of FORD MOTOR CO.
Install the starter motor isolator.

Fig 10: Locating Starter Motor Isolator
Courtesy of FORD MOTOR CO.
Install the starter motor. For additional information, refer to STARTING SYSTEM .
Connect the Turbine Shaft Speed (TSS) sensor electrical connector.

Fig 11: Locating Turbine Shaft Speed (TSS) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the transaxle vehicle harness electrical connector.

Fig 12: Locating Transaxle Vehicle Harness Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the transaxle electrical wiring harness retainers.

Fig 13: Locating Transaxle Electrical Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
Position the transmission fluid cooler tubes in place. Install the transmission fluid cooler tubes in the transaxle by inserting the tube into the fitting until a click is heard/felt. Pull back to confirm connection is secure and install the transmission fluid cooler tube secondary latches.

Fig 14: Locating Transmission Fluid Cooler Tube Secondary Latches
Courtesy of FORD MOTOR CO.

Front Wheel Drive (FWD) vehicles
Install the dampener and the 3 dampener bolts, 2 from the RH side of the transaxle and 1 from the LH side.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 15: Locating Dampener Bolts
  Courtesy of FORD MOTOR CO.
All-Wheel Drive (AWD) vehicles
Install the Power Transfer Unit (PTU) and install the bolt.
- Tighten to 70 Nm (52 lb-ft).
  
  Fig 16: Locating PTU And Bolt
  Courtesy of FORD MOTOR CO.

NOTE: Exhaust removed for clarity.

Install the PTU bolts.
- Tighten to 70 Nm (52 lb-ft).
  
  Fig 17: Locating PTU Bolts
  Courtesy of FORD MOTOR CO.
Install the PTU bracket and the 2 PTU bracket bolts.
- Tighten to 45 Nm (33 lb-ft).
  
  Fig 18: Locating PTU Bracket-To-PTU Bolts And Bracket
  Courtesy of FORD MOTOR CO.
Install the PTU bracket-to-engine bolt.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 19: Locating PTU Bracket-To-Engine Bolt
  Courtesy of FORD MOTOR CO.
Install the 4 PTU bracket-to-engine bolts.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 20: Locating PTU Bracket-To-Engine Bolts
  Courtesy of FORD MOTOR CO.
Install the 2 catalytic converter support bracket bolts.
- Tighten to 20 Nm (177 lb-in).
  
  Fig 21: Locating Exhaust Bracket-To-Intermediate Shaft Bracket Bolts
  Courtesy of FORD MOTOR CO.
All vehicles
Install the lower front insulator bracket and 3 nuts.
- Tighten to 48 Nm (35 lb-ft).
  
  Fig 22: Locating Transaxle Front Mount Bracket Bolts
  Courtesy of FORD MOTOR CO.
Install the engine support cross brace and new cross brace nut.
- Tighten to 175 Nm (129 lb-ft).
  
  Fig 23: Locating Cross Brace Nut And Brace
  Courtesy of FORD MOTOR CO.
Install the 2 bolts for the cross brace and the lower front insulator through bolt.
- Tighten the cross brace bolts to 90 Nm (66 lb-ft).
- Tighten the lower front insulator through bolt to 115 Nm (85 lb-ft).
  
  Fig 24: Locating Lower Front Insulator Through Bolt And Cross Brace Bolts
  Courtesy of FORD MOTOR CO.
Install the rear cross brace and the 4 bolts.
- Tighten to 115 Nm (85 lb-ft).
  
  Fig 25: Locating Rear Cross Brace Bolts
  Courtesy of FORD MOTOR CO.
Install the LH front halfshaft and the intermediate shaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
AWD vehicles
Position the driveshaft to the PTU and install the 6 driveshaft bolts.
- Tighten to 37 Nm (27 lb-ft).
  
  Fig 26: Locating Driveshaft Bolts
  Courtesy of FORD MOTOR CO.
All vehicles

NOTE: AWD shown, FWD similar.

Install the lower support insulator.
1. Install the lower support insulator bolt and 2 nuts.
  - Tighten to 80 Nm (59 lb-ft).
2. Install the damper, if equipped and the lower support insulator through bolt.
  - Tighten to 115 Nm (85 lb-ft).
    
    Fig 27: Identifying Lower Support Insulator Bolt And Nuts
    Courtesy of FORD MOTOR CO.
Install the LH splash shield and 7 retainers.

Fig 28: Locating LH Splash Shield Retainer
Courtesy of FORD MOTOR CO.
Install the RH splash shield and 6 retainers.

Fig 29: Locating RH Splash Shield Retainers
Courtesy of FORD MOTOR CO.
Install the front wheels and tires. For additional information, refer to WHEELS & TIRES .

NOTE: Transaxle removed for clarity.

Install the 3 upper torque converter housing bolts.
- Tighten to 48 Nm (35 lb-ft).
  
  Fig 30: Locating Upper Transaxle Retaining Bolts
  Courtesy of FORD MOTOR CO.
Install the selector lever cable retainer to the transaxle filler tube bracket.

Fig 31: Locating Selector Lever Cable Retainer
Courtesy of FORD MOTOR CO.
Position the selector lever cable and bracket in place and install the 2 retaining bolts.
- Tighten to 12 Nm (106 lb-in).
  
  Fig 32: Locating Selector Lever Cable Bracket Retaining Bolts
  Courtesy of FORD MOTOR CO.
Connect the selector lever cable end to the manual control lever with the manual control lever and selector lever in DRIVE. Check the selector lever cable adjustment. For additional information, refer to AUTOMATIC TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS - 6F35 .

Fig 33: Connecting Selector Lever Cable End To Manual Control Lever
Courtesy of FORD MOTOR CO.
Install the Air Cleaner (ACL) and outlet pipe assembly. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING - 2.5L .
Install the battery tray and battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
Fill with clean transmission fluid to the correct level.