Transaxle - 3.0L

Illustration	Tool Name	Tool Number
Courtesy of FORD MOTOR CO.	Adapters for 303-290	303-290A-01
Courtesy of FORD MOTOR CO.	Adapter for 303-290-A (Support Leg)	303-290A-03A
Courtesy of FORD MOTOR CO.	Alignment Gauge, TR Sensor	307-351 (T97L-70010-A)
Courtesy of FORD MOTOR CO.	Engine Lifting Chains (Part of Spreader Bar)	303-D089 (D93P-6001-A3) or equivalent
Courtesy of FORD MOTOR CO.	Lifting Bracket, Engine	303-050 (T70P-6000)
Courtesy of FORD MOTOR CO.	Retainer, Torque Converter	307-346 (T97T-7902-A)
Courtesy of FORD MOTOR CO.	Support Bar, Engine	303-290A

All vehicles 

1. Lubricate the torque converter pilot hub with grease.
Fig 1: Identifying Torque Converter Pilot Hub
Courtesy of FORD MOTOR CO.
2. Install the special tool.
Fig 2: Identifying Special Tool
Courtesy of FORD MOTOR CO.
3. Position the transaxle in place.
Fig 3: Lowering Transaxle From Engine Compartment
Courtesy of FORD MOTOR CO.
4. Once the transaxle is in place, before bolting it to the engine, remove the special tool.
Fig 4: Identifying Special Tool
Courtesy of FORD MOTOR CO.
5. Move the transaxle assembly toward the engine assembly and install the bolt.
   • Tighten to 48 Nm (35 lb-ft).
Fig 5: Locating Bolt
Courtesy of FORD MOTOR CO.
6. Install the 2 nuts and the stud.
   • Tighten to 48 Nm (35 lb-ft).
Fig 6: Locating Transaxle Bolt
Courtesy of FORD MOTOR CO.
7. Install the lower transaxle bolts.
   • Tighten to 48 Nm (35 lb-ft).
Fig 7: Locating Lower Transaxle Bolts
Courtesy of FORD MOTOR CO.
8. Install the lower rear mount bracket.
   • Tighten to 55 Nm (41 lb-ft).
Fig 8: Locating Transaxle Mount Bracket
Courtesy of FORD MOTOR CO.
9. Loosely install the lower support insulator through bolt.
Fig 9: Locating Rear Transaxle Mount Bolt
Courtesy of FORD MOTOR CO.
10. Install the LH transaxle mount through bolt.
Fig 10: Identifying Through Bolt
Courtesy of FORD MOTOR CO.
11. Tighten the lower support insulator through bolt.
    • Tighten to 115 Nm (85 lb-ft).
Fig 11: Locating Rear Transaxle Mount Bolt
Courtesy of FORD MOTOR CO.
12. Install the transmission fluid cooler tube.
    • Tighten to 25 Nm (18 lb-ft).
Fig 12: Locating Transmission Fluid Cooler Tube
Courtesy of FORD MOTOR CO.
13. Install the transmission fluid cooler tube.
    1. Install the fluid cooler tube.
       • Tighten to 25 Nm (18 lb-ft).
    2. Install the transmission fluid cooler tube bolt.
       • Tighten to 12 Nm (9 lb-ft).
Fig 13: Identifying Fluid Cooler Tube And Bolt
Courtesy of FORD MOTOR CO.
14. Install the output shaft speed (OSS) sensor and the bolt.
    • Tighten to 12 Nm (9 lb-ft).
Fig 14: Locating OSS Sensor Bolt
Courtesy of FORD MOTOR CO.
15. Connect the OSS speed sensor and the turbine shaft speed (TSS) sensor electrical connectors and connect the wiring harness fasteners.
16. Install 4 new torque converter nuts.
    • Tighten to 40 Nm (30 lb-ft).
Fig 15: Locating Torque Converter Nuts
Courtesy of FORD MOTOR CO.
17. Install the access cover.
Fig 16: Locating Access Cover
Courtesy of FORD MOTOR CO.

All wheel drive (AWD) vehicles 

18. Position the power transfer unit (PTU) in place and install the bolt.
    • Tighten to 47 Nm (35 lb-ft).
Fig 17: Locating Transfer Case Bolt & Transfer Case Unit
Courtesy of FORD MOTOR CO.
19. Install the PTU-to-transaxle bolts.
    • Tighten to 70 Nm (52 lb-ft).
Fig 18: Locating PTU Bolts
Courtesy of FORD MOTOR CO.

All vehicles 

20. Connect the electrical connector fasteners to the lower mount bracket.
Fig 19: Locating Electrical Connectors At Lower Mount Bracket
Courtesy of FORD MOTOR CO.
21. Position the cross brace in place and install the nut.
    • Tighten to 175 Nm (129 lb-ft).
Fig 20: Identifying Cross Brace And Rear Nut
Courtesy of FORD MOTOR CO.
22. Install the 2 bolts for the cross brace.
    • Tighten to 90 Nm (66 lb-ft).
Fig 21: Locating Cross Brace Bolts
Courtesy of FORD MOTOR CO.
23. Install the lower front insulator bolt for the mount.
    • Tighten to 103 Nm (76 lb-ft).
Fig 22: Locating Mount Through Bolt
Courtesy of FORD MOTOR CO.

AWD vehicles 

24. Install the PTU support bracket.
    • Tighten to 55 Nm (41 lb-ft).
Fig 23: Locating Bolts & Bracket
Courtesy of FORD MOTOR CO.
25. Install the RH catalytic converter. For additional information, refer to EXHAUST SYSTEM article.
26. Position the driveshaft in place and install the nuts.
    • Tighten to 48 Nm (35 lb-ft).
Fig 24: Locating Center Bearing Nuts
Courtesy of FORD MOTOR CO.
27. Connect the rear driveshaft to the PTU. Install the PTU bolts.
    • Tighten to 37 Nm (27 lb-ft).
Fig 25: Locating Driveshaft & Bolts
Courtesy of FORD MOTOR CO.

All vehicles 

28. Install the Y-pipe and connect the exhaust pipe flange.
    • Tighten to 29 Nm (21 lb-ft).
Fig 26: Rear Exhaust Pipe Flange & Nuts
Courtesy of FORD MOTOR CO.
29. Connect the front flange.
    • Tighten to 29 Nm (21 lb-ft).
Fig 27: Front Exhaust Pipe Flange Nuts
Courtesy of FORD MOTOR CO.
30. Install the exhaust pipe.
    1. Install the rubber hanger.
    2. Install the exhaust pipe and install the bolts.
       • Tighten to 29 Nm (21 lb-ft).
Fig 28: Exhaust Hanger & Nuts
Courtesy of FORD MOTOR CO.
31. Install the rear cross brace and 4 bolts.
    • Tighten to 115 Nm (85 lb-ft).
Fig 29: Locating Cross Brace & Bolts
Courtesy of FORD MOTOR CO.
32. Install the intermediate shaft.
Fig 30: Locating Intermediate Shaft
Courtesy of FORD MOTOR CO.
33. Install the intermediate shaft retaining nuts.
    • Tighten to 27 Nm (20 lb-ft).
Fig 31: Locating Intermediate Shaft Retaining Nuts
Courtesy of FORD MOTOR CO.
34. Connect the heated oxygen sensor (HO2S) wire to the oil pan bolt studs and connect the connector.
Fig 32: Locating HO2S Sensor Connector
Courtesy of FORD MOTOR CO.
35. Install the LH halfshaft into the transaxle and the RH halfshafts in the intermediate shaft and install the ball joints in the knuckles.
36. Install the LH brake hose retainer and the ABS sensor bolt.
    • Tighten to 15 Nm (11 lb-ft).
Fig 33: Identifying Retainer And Bolt
Courtesy of FORD MOTOR CO.
37. Install the RH brake hose retainer and the ABS sensor bolt.
    • Tighten to 15 Nm (11 lb-ft).
Fig 34: Identifying Retainer And Bolt
Courtesy of FORD MOTOR CO.
38. 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 35: Identifying Bolt, Nut And Stabilizer Bar Link
Courtesy of FORD MOTOR CO.
39. 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 36: Identifying Bolt, Nut And Stabilizer Bar Link
Courtesy of FORD MOTOR CO.
40. Install the LH splash shield, the retainer and the 5 bolts.
Fig 37: View Of LH Splash Shield And Retainers
Courtesy of FORD MOTOR CO.
41. Install the RH splash shield, the retainer and the 5 bolts.
Fig 38: Right Splash Shield Bolts
Courtesy of FORD MOTOR CO.
42. Install the front wheels and tires. For additional information, refer to WHEELS AND TIRES article.
43. Using the special tools, lower the engine onto the RH engine mount.
Fig 39: Locating Lowering Engine Onto RH Engine Mount
Courtesy of FORD MOTOR CO.
44. Install the bolt for the RH engine mount.
    • Tighten to 120 Nm (89 lb-ft).
Fig 40: Identifying Bolt
Courtesy of FORD MOTOR CO.
45. Tighten the LH support insulator mount assembly.
    1. Tighten the 4 nuts for the bracket.
       • Tighten to 40 Nm (30 lb-ft).
    2. Tighten the through bolt.
       • Tighten to 103 Nm (76 lb-ft).
Fig 41: Locating LH Upper Transaxle Mount Assembly Bolt
Courtesy of FORD MOTOR CO.
46. Install the 4 upper transaxle retaining bolts.
    • Tighten to 48 Nm (35 lb-ft).
Fig 42: Identifying Bolts
Courtesy of FORD MOTOR CO.
47. Remove the special tools.
Fig 43: Identifying Special Tools
Courtesy of FORD MOTOR CO.
48. Remove the special tools.
Fig 44: Identifying Special Tools
Courtesy of FORD MOTOR CO.
49. Remove the special tools.
Fig 45: Drivetrain Support Tool
Courtesy of FORD MOTOR CO.
50. Remove the special tool.
Fig 46: Identifying Special Tool
Courtesy of FORD MOTOR CO.
51. Connect the electrical connectors together and then connect them to the upper intake manifold.
Fig 47: Locating Electrical Connectors
Courtesy of FORD MOTOR CO.
52. Install the starter motor and install the bolts.
    • Tighten to 25 Nm (18 lb-ft).
Fig 48: Locating Starter Bolts & Starter Motor
Courtesy of FORD MOTOR CO.
53. Install the ground cable.
    • Tighten to 27 Nm (20 lb-ft).
Fig 49: Locating Ground Cable
Courtesy of FORD MOTOR CO.
54. Install the starter motor solenoid 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 50: Locating Starter Motor Harness Connector & Nut
Courtesy of FORD MOTOR CO.
55. 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 51: Identifying Harness Retainer And Bolts
Courtesy of FORD MOTOR CO.
56. Connect the selector lever cable to the manual control lever.
Fig 52: Identifying Gearshift Cable
Courtesy of FORD MOTOR CO.
57. Install the selector lever cable retainer on the transmission fluid filler tube.
Fig 53: Identifying Selector Lever Cable Retainer
Courtesy of FORD MOTOR CO.
58. Connect the wire harness to the battery hold-down bracket.
Fig 54: Locating Wire Harness Bracket
Courtesy of FORD MOTOR CO.

AWD vehicles 

59. Connect the evaporative emissions (EVAP) and PTU vent hose to the transmission filler tube bracket.
Fig 55: Identifying PTU Vent Hose
Courtesy of FORD MOTOR CO.

All vehicles 

60. Install the main control cover vent tube.
Fig 56: Locating Main Control Cover Vent Tube
Courtesy of FORD MOTOR CO.
61. Position the bracket in place and install the nut. Connect the transaxle harness connector.
    • Tighten to 25 Nm (18 lb-ft).
Fig 57: Locating Transaxle Harness Connector & Nut
Courtesy of FORD MOTOR CO.
62. Connect the transmission range (TR) sensor.
Fig 58: Locating Transmission Range (TR) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
NOTE: If installing an exchange transaxle, the digital TR sensor must be aligned.
63. Using the special tool, align the digital TR sensor.
    • Tighten to 10 Nm (89 lb-in).
Fig 59: Aligning Digital TR Sensor
Courtesy of FORD MOTOR CO.
64. Install the air cleaner as an assembly.
    1. Install the air cleaner assembly.
    2. Connect the air intake tube.
    3. Install the retaining bolt.
       • Tighten to 10 Nm (89 lb-in).
    4. Install the breather tube.
    5. Connect the mass air flow (MAF) sensor electrical connector.
Fig 60: Identifying Air Cleaner Assembly
Courtesy of FORD MOTOR CO.
NOTE: Before installing the battery tray, check the vent tube hose for any obstructions, kinks or incorrect routing position.
65. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
66. Fill the transaxle with clean transmission fluid.
67. 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.
68. Check the transmission fluid level and correct as necessary.