Transaxle - 2.3L: Installation

All vehicles 

1. Lubricate the torque converter pilot hub with grease.
Fig 1: Identifying Torque Converter Pilot Hub
Courtesy 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
Courtesy of FORD MOTOR CO.
4. Position the transaxle in place.
Fig 3: Lowering Transaxle From Engine Compartment
Courtesy 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
Courtesy of FORD MOTOR CO.
6. Move the transaxle assembly toward the engine assembly and install the 4 bolts.
   • Tighten to 48 Nm (35 lb-ft).
Fig 5: Locating Transaxle-To-Engine Bolts
Courtesy of FORD MOTOR CO.
7. Install the transaxle retaining bolts.
   • Tighten to 48 Nm (35 lb-ft).
Fig 6: Locating Rear Bellhousing Bolts
Courtesy of FORD MOTOR CO.
8. Install 4 new torque converter nuts.
   • Tighten to 40 Nm (30 lb-ft).
Fig 7: Locating Torque Converter Nut
Courtesy of FORD MOTOR CO.
9. Install the transmission fluid cooler tube.
   • Tighten to 25 Nm (18 lb-ft).
Fig 8: Locating Transmission Fluid Cooler Tube
Courtesy of FORD MOTOR CO.
10. Install the output shaft speed (OSS) sensor.
    • Tighten to 12 Nm (9 lb-ft).
Fig 9: Locating OSS Sensor Bolt
Courtesy of FORD MOTOR CO.
11. Install the transmission fluid cooler tube.
    1. Connect the OSS sensor connector (black).
    2. Connect the turbine shaft speed (TSS) sensor connector (white).
       • Connect the wiring harness retainer to the transaxle case.
    3. Install the transmission fluid cooler tube.
       • Tighten to 25 Nm (18 lb-ft).
    4. Install the transmission fluid cooler bolt.
       • Tighten to 12 Nm (9 lb-ft).
Fig 10: Identifying Fluid Cooler Tube Components
Courtesy of FORD MOTOR CO.
12. Install the starter motor isolator.
Fig 11: Identifying Starter Motor Isolator
Courtesy of FORD MOTOR CO.
13. Install the starter motor.
    • Tighten to 35 Nm (26 lb-ft).
Fig 12: Identifying Bolts
Courtesy of FORD MOTOR CO.
14. Install the starter motor harness connector.
    1. Install the starter motor solenoid battery nut.
       • Tighten to 12 Nm (9 lb-ft).
    2. Install the starter motor solenoid nut.
       • Tighten to 5 Nm (44 lb-in).
Fig 13: Identifying Battery Cable & Starter Solenoid Terminal Nut
Courtesy of FORD MOTOR CO.
15. Install the wire harness clip retainer and the ground wire to starter bolts.
    • Tighten to 25 Nm (18 lb-ft).
Fig 14: Locating Wire Harness Clip Retainer & Starter Bolts
Courtesy of FORD MOTOR CO.
16. Install the front mount bracket.
    • Tighten to 48 Nm (35 lb-ft).
Fig 15: Locating Transaxle Front Mount Plate Bolts
Courtesy of FORD MOTOR CO.
17. Using the special tools, raise the transaxle.
Fig 16: Special Tool
Courtesy of FORD MOTOR CO.
18. Install the LH upper transaxle mount through bolt.
    • Tighten to 103 Nm (76 lb-ft).
Fig 17: Locating LH Transaxle Mount Through Bolt
Courtesy of FORD MOTOR CO.
19. Remove the special tools.
Fig 18: Special Tool
Courtesy of FORD MOTOR CO.
20. Remove the special tools.
Fig 19: Special Tool
Courtesy of FORD MOTOR CO.
21. Install the upper transaxle bolts.
    • Tighten to 48 Nm (35 lb-ft).
Fig 20: Locating Upper Transaxle Bolts
Courtesy of FORD MOTOR CO.
22. Connect the transmission range (TR) sensor electrical connector.
Fig 21: Locating Transmission Range (TR) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
23. Position the selector lever cable and bracket in place, install the bolts and install the wiring harness retainer.
    • Tighten to 23 Nm (17 lb-ft).
Fig 22: Identifying Harness Retainer And Bolts
Courtesy of FORD MOTOR CO.
24. Connect the selector lever cable to the manual control lever.
Fig 23: Identifying Gearshift Cable
Courtesy of FORD MOTOR CO.
25. Install the selector lever cable retainer on the transmission fluid filler tube.
Fig 24: Identifying Selector Lever Cable Retainer
Courtesy of FORD MOTOR CO.
26. Install the main control cover vent tube.
Fig 25: Locating Main Control Cover Vent Tube
Courtesy of FORD MOTOR CO.
27. Install the wire harness bracket nut and plug in the bulkhead electrical connector.
    • Tighten to 25 Nm (18 lb-ft).
Fig 26: Locating Wire Harness Bracket Nut & Plug
Courtesy of FORD MOTOR CO.
28. Install the rear transaxle mount, 2 nuts and bolt.
    • Tighten to 80 Nm (59 lb-ft).
Fig 27: Locating Rear Transmission Mount Bolts
Courtesy of FORD MOTOR CO.
29. Install the lower support insulator through bolt.
    • Tighten to 115 Nm (85 lb-ft).
Fig 28: Locating Rear Transaxle Mount Bolt
Courtesy of FORD MOTOR CO.

Front wheel drive (FWD) vehicles 

30. Install the dampener.
    1. Install the bolts.
       • Tighten to 70 Nm (52 lb-ft).
    2. Install the bolt.
       • Tighten to 47 Nm (35 lb-ft).
Fig 29: Identifying Bolts
Courtesy of FORD MOTOR CO.

All wheel drive (AWD) vehicles 

31. Position the power transfer unit (PTU) in place and install the bolt.
    • Tighten to 47 Nm (35 lb-ft).
Fig 30: Locating Transfer Case Bolt & Transfer Case Unit
Courtesy of FORD MOTOR CO.
32. Install the PTU-to-transaxle bolts.
    • Tighten to 70 Nm (52 lb-ft).
Fig 31: Locating PTU Bolts
Courtesy of FORD MOTOR CO.
33. Position the driveshaft in place and install the nuts.
    • Tighten to 48 Nm (35 lb-ft).
Fig 32: Locating Center Bearing Nuts
Courtesy of FORD MOTOR CO.
34. Align the index marks and install the driveshaft.
    • Tighten to 20 Nm (15 lb-ft).
Fig 33: Locating Driveshaft & Bolts
Courtesy of FORD MOTOR CO.
35. Install the bracket.
    • Tighten to 55 Nm (41 lb-ft).
Fig 34: Locating Engine Mounting Bracket Bolts
Courtesy of FORD MOTOR CO.
36. Install the front nuts on the exhaust-to-intermediate shaft bracket.
    • Tighten to 30 Nm (22 lb-ft).
Fig 35: Locating Exhaust-To-Intermediate Shaft Bracket Nuts
Courtesy of FORD MOTOR CO.
37. Install the bolts on the rear of the exhaust-to-intermediate shaft bracket.
    • Tighten to 30 Nm (22 lb-ft).
Fig 36: Locating Bolts On Rear Of Exhaust-To-Intermediate Shaft Bracket
Courtesy of FORD MOTOR CO.

All vehicles 

38. Install the flexpipe on the exhaust manifold and install the nuts.
    • Tighten to 25 Nm (18 lb-ft).
Fig 37: Locating Flexpipe On Exhaust Manifold & Nuts
Courtesy of FORD MOTOR CO.
39. Install the intermediate shaft.
Fig 38: Locating Intermediate Shaft
Courtesy of FORD MOTOR CO.
40. Install the intermediate shaft retaining nuts.
    • Tighten to 27 Nm (20 lb-ft).
Fig 39: Locating Intermediate Shaft Retaining Nuts
Courtesy of FORD MOTOR CO.
41. Install the LH and RH halfshafts in the transaxle and install the ball joints in the knuckles.
42. Install the LH brake hose retainer and the ABS sensor bolt.
    • Tighten to 15 Nm (11 lb-ft).
Fig 40: Identifying Retainer And Bolt
Courtesy of FORD MOTOR CO.
43. Install the RH brake hose retainer and the ABS sensor bolt.
    • Tighten to 15 Nm (11 lb-ft).
Fig 41: Identifying Retainer And Bolt
Courtesy of FORD MOTOR CO.
44. Connect the LH suspension.
    1. Install the lower ball joint-to-knuckle bolt.
       • Tighten to 63 Nm (46 lb-ft).
    2. Install the tie-rod end retaining nut.
       • Tighten to 55 Nm (41 lb-ft).
    3. Connect the stabilizer bar link.
       • Tighten to 63 Nm (46 lb-ft).
Fig 42: Identifying Bolt, Nut And Stabilizer Bar Link
Courtesy of FORD MOTOR CO.
45. Connect the RH suspension.
    1. Install the lower ball joint-to-knuckle bolt.
       • Tighten to 63 Nm (46 lb-ft).
    2. Install the tie-rod end retaining nut.
       • Tighten to 55 Nm (41 lb-ft).
    3. Connect the stabilizer bar link.
       • Tighten to 63 Nm (46 lb-ft).
Fig 43: Identifying Bolt, Nut And Stabilizer Bar Link
Courtesy of FORD MOTOR CO.
46. Position the cross brace in place and install the nut.
    • Tighten to 175 Nm (129 lb-ft).
Fig 44: Identifying Cross Brace And Rear Nut
Courtesy of FORD MOTOR CO.
47. Install the 2 bolts for the cross brace.
    • Tighten to 90 Nm (66 lb-ft).
Fig 45: Locating Cross Brace Bolts
Courtesy of FORD MOTOR CO.
48. Install the lower front support insulator bolt for the mount.
    • Tighten to 103 Nm (76 lb-ft).
Fig 46: Locating Mount Through Bolt
Courtesy of FORD MOTOR CO.
49. Install the cross brace and the 4 bolts.
    • Tighten to 115 Nm (85 lb-ft).
Fig 47: Locating Cross Brace & Bolts
Courtesy of FORD MOTOR CO.
50. Install the LH splash shield and the 7 retainers.
Fig 48: View Of LH Splash Shield And Retainers
Courtesy of FORD MOTOR CO.
51. Install the RH splash shield and the 5 retainers.
Fig 49: Right Splash Shield Bolts
Courtesy of FORD MOTOR CO.
52. Install the front wheels and tires. For additional information, refer to WHEELS AND TIRES article.

AWD vehicles 

53. Install the vent tube to the transmission fluid filler tube.
Fig 50: Locating Power Transfer Unit (PTU) Vent Hose
Courtesy of FORD MOTOR CO.

All vehicles 

54. Install the air cleaner assembly.
    1. Install the bolt.
       • Tighten to 10 Nm (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 51: Identifying Air Cleaner Assembly
Courtesy of FORD MOTOR CO.
55. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
56. Fill the transaxle with clean transmission fluid.
57. Verify that the selector lever cable is correctly adjusted. The vehicle should start in PARK and NEUTRAL and the reverse lamps should illuminate in REVERSE. For additional information, refer to AUTOMATIC TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS - CD4E article.
58. Check the transmission fluid level and correct as necessary.