Transaxle - 3.0L: Material

All vehicles 

1. Lubricate the torque converter pilot hub with grease.
   Fig 1: Locating Torque Converter Pilot Hub

   Courtesy of FORD MOTOR CO.
2. Install the Torque Converter Retainer.
   Fig 2: View Of Torque Converter Retainer

   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 Torque Converter Retainer.
   Fig 4: View Of Torque Converter Retainer

   Courtesy of FORD MOTOR CO.
5. Move the transaxle assembly toward the engine assembly and install the transaxle converter housing bolt.
   • Tighten to 48 Nm (35 lb-ft).
     Fig 5: Locating Transaxle Converter Housing Bolt

     Courtesy of FORD MOTOR CO.
6. Install the torque converter housing nut and the stud.
   • Tighten to 48 Nm (35 lb-ft).
     Fig 6: Identifying Torque Converter Housing Nut And Stud

     Courtesy of FORD MOTOR CO.
7. Install the 2 oil pan-to-transaxle bolts.
   • Tighten to 48 Nm (35 lb-ft).
     Fig 7: Remove/Install Oil Pan-To-Transaxle Bolts

     Courtesy of FORD MOTOR CO.
8. 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 8: Locating Transmission Fluid Cooler Tube Secondary Latches

   Courtesy of FORD MOTOR CO.
9. Connect the Turbine Shaft Speed (TSS) sensor electrical connector.
   Fig 9: Locating Turbine Shaft Speed Sensor Electrical Connector

   Courtesy of FORD MOTOR CO.
10. Connect the transaxle vehicle harness electrical connector.
    Fig 10: View Of Transaxle Vehicle Harness Electrical Connector

    Courtesy of FORD MOTOR CO.
11. Connect the transaxle electrical wiring harness retainers to the main control cover stud bolts.
    Fig 11: Locating Transaxle Electrical Wiring Harness Retainers

    Courtesy of FORD MOTOR CO.
12. Install 4 new torque converter nuts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 12: Locating Torque Converter Nuts

      Courtesy of FORD MOTOR CO.
13. Install the access cover.
    Fig 13: Locating Access Cover

    Courtesy of FORD MOTOR CO.
14. Position the transaxle support insulator bracket in place and install the 4 nuts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 14: Locating Transaxle Support Insulator Bracket Nuts

      Courtesy of FORD MOTOR CO.
15. 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 15: Raising Transaxle Using Engine Support Bar And Adapters

      Courtesy of FORD MOTOR CO.
16. Remove the Engine Support Bar and Adapters.
    Fig 16: View Of Engine Support Bar, Support Leg And Adapters

    Courtesy of FORD MOTOR CO.
17. Remove the Engine Lifting Brackets and the Universal Adapter Brackets from the cylinder heads.
    Fig 17: View Of Engine Lifting Bracket And Universal Mounting Brackets

    Courtesy of FORD MOTOR CO.

    All-Wheel Drive (AWD) vehicles 

18. Position the Power Transfer Unit (PTU) in place and install the PTU  bolt.
    • Tighten to 70 Nm (52 lb-ft).
      Fig 18: Remove/Install PTU And Bolt

      Courtesy of FORD MOTOR CO.
19. Install the PTU  bolts.
    • Tighten to 70 Nm (52 lb-ft).
      Fig 19: Remove/Install PTU Bolts

      Courtesy of FORD MOTOR CO.
20. Install the PTU  support bracket and bolts.
    • Tighten to 55 Nm (41 lb-ft).
      Fig 20: Locating PTU Support Bracket Bolts

      Courtesy of FORD MOTOR CO.
NOTE: Prior to installation, inspect the Catalyst Monitor Sensor (CMS) wiring harness for damage.
21. Install the RH catalytic converter and the 3 nuts.
    • Tighten to 40 Nm (30 lb-ft).
22. Connect the rear driveshaft to the PTU  . Install the driveshaft bolts.
    • Tighten to 37 Nm (27 lb-ft).
      Fig 21: Locating Driveshaft Bolts

      Courtesy of FORD MOTOR CO.

    All vehicles 

NOTE: AWD  shown in the illustration, FWD  similar.
23. 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 22: Identifying Lower Support Insulator Bolt And Nuts

         Courtesy of FORD MOTOR CO.
24. Position the exhaust Y-pipe in place and install 6 new exhaust Y-pipe nuts.
    • Install the 2 new 10-mm catalytic converter-to-exhaust exhaust Y-pipe spring nuts and alternately tighten RH side to LH side in sequence in 3 stages:
      • Stage 1: Tighten to 5 Nm (44 lb-in).
      • Stage 2: Tighten to 15 Nm (133 lb-in).
      • Stage 3: Tighten to 25 Nm (18 lb-ft).
    • Tighten the 4 remaining exhaust Y-pipe nuts to 25 Nm (18 lb-ft).
      Fig 23: Locating Exhaust Y-Pipe Nuts

      Courtesy of FORD MOTOR CO.
25. Connect the LH CMS electrical connector.
    Fig 24: Locating LH Catalyst Monitor Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
26. Connect the RH CMS electrical connector.
    Fig 25: Locating RH CMS Electrical Connector

    Courtesy of FORD MOTOR CO.
27. Install the lower front insulator mount bracket.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 26: Remove/Install Lower Front Insulator Bracket Nuts

      Courtesy of FORD MOTOR CO.
28. Position the cross brace in place and install the nut.
    • Tighten to 175 Nm (129 lb-ft).
      Fig 27: View Of Cross Brace And Nut

      Courtesy of FORD MOTOR CO.
29. Install the 2 bolts for the cross brace and the lower front insulator mount through bolt.
    • Tighten the cross brace bolts to 90 Nm (66 lb-ft).
    • Tighten the lower front insulator mount through bolt to 115 Nm (85 lb-ft).
      Fig 28: View Of Lower Front Insulator Through Bolt And Cross Brace Bolts

      Courtesy of FORD MOTOR CO.
30. Install the rear cross brace and 4 bolts.
    • Tighten to 115 Nm (85 lb-ft).
      Fig 29: Remove/Install Rear Cross Brace Bolts

      Courtesy of FORD MOTOR CO.
31. Install the LH front halfshaft and intermediate shaft. For additional information, refer to FRONT DRIVE HALFSHAFTS article.
32. Install the LH splash shield, the retainer and the bolts.
    Fig 30: Locating LH Splash Shield Retainers

    Courtesy of FORD MOTOR CO.
33. Install the RH splash shield, the retainer and the bolts.
    Fig 31: Locating RH Splash Shield Retainers

    Courtesy of FORD MOTOR CO.
34. Install the front wheels and tires. For additional information, refer to TIRES & WHEELS article.
35. Install the 4 upper transaxle torque converter housing bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 32: Remove/Install Upper Transaxle Retaining Bolts

      Courtesy of FORD MOTOR CO.
36. Install the starter motor. For additional information, refer to STARTING SYSTEM article.
37. Position the selector lever cable and bracket in place and install the 2 retaining bolts.
    • Tighten to 12 Nm (106 lb-in).
      Fig 33: Remove/Install Selector Lever Cable With Bracket And Retaining Bolts

      Courtesy of FORD MOTOR CO.
38. Connect the selector lever cable end to the manual control lever.
    Fig 34: Connecting Selector Lever Cable End To Manual Control Lever

    Courtesy of FORD MOTOR CO.
39. Install the selector lever cable retainer on the transaxle filler tube.
    Fig 35: Locating Transaxle Filler Tube Bracket

    Courtesy of FORD MOTOR CO.

    AWD vehicles 

40. Connect the PTU  vent hose to the transaxle filler tube bracket.
    Fig 36: Locating Transaxle Filler Tube

    Courtesy of FORD MOTOR CO.

    All vehicles 

41. Install the Air Cleaner (ACL) and outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - 3.0L (4V) article.
42. Install the battery tray and battery. For additional information, refer to BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES article.
43. Fill the transaxle with clean transmission fluid.
44. Start the engine and move the range selector lever into each gear position.
45. 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 - 6F35 article.
46. Using the scan tool with the engine running, check and make sure that the transmission is at normal operating temperature 85-93°C (185-200°F). Check and adjust the transmission fluid level and check for any leaks. If transmission fluid is needed, add transmission fluid in increments of 0.24L (0.5 pt) until the correct level is achieved.
47. If a new solenoid body is installed, the solenoid body strategy and solenoid body identification will need to be updated. For additional information, refer to SOLENOID BODY STRATEGY  in this service information.
48. If a replacement transaxle assembly is being installed or a new solenoid body is installed, the PCM will have to be reflashed with a new solenoid body strategy and identification data file. For additional information, refer to SOLENOID BODY STRATEGY  in this service information.
49. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.