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Removal And Installation: Transaxle: Installation

WARNING: This page is about a different variant/trim than selected.
  1. Install the new engine-to-transaxle separator plate.
    NOTE: Use caution not to damage the engine-to-transaxle separator plate or damage can occur.
    Fig 1: Locating Engine-To-Transaxle Separator Plate
    G06939374Courtesy of FORD MOTOR CO.
  2. Using a suitable tool, remove and discard the LH halfshaft seal.
    NOTE: If using the old transaxle, the halfshaft seals must be replaced or damage to the transaxle can occur.
    Fig 2: Locating LH Halfshaft Seal
    G06939375Courtesy of FORD MOTOR CO.
  3. Install the new LH halfshaft seal onto the special tool.
    Fig 3: Installing LH Halfshaft Seal On Special Tool
    G06939376Courtesy of FORD MOTOR CO.
  4. Using the special tools, install the new LH halfshaft seal.
    Fig 4: Installing LH Halfshaft Seal Using Special Tools
    G06939377Courtesy of FORD MOTOR CO.
  5. Using a suitable tool. remove and discard the RH halfshaft seal.
    Fig 5: Locating RH Halfshaft Seal
    G06939378Courtesy of FORD MOTOR CO.
  6. Install the new RH halfshaft seal onto the special tool.
    Fig 6: Installing RH Halfshaft Seal On Special Tool
    G06939379Courtesy of FORD MOTOR CO.
  7. Using the special tools, install the new RH halfshaft seal.
    Fig 7: Installing RH Halfshaft Seal On Special Tool
    G06939380Courtesy of FORD MOTOR CO.
  8. If using a new clutch assembly, make sure the clutch-to-flexplate alignment marks are aligned.
    Fig 8: Locating Clutch-To-Flexplate Alignment Marks
    G06939381Courtesy of FORD MOTOR CO.
  9. Install the transaxle.
    NOTE: Align the marks on the flexplate and stud made during removal.
    Fig 9: Positioning Suitable High-Lift Transmission Jack Under Transaxle And Transaxle
    G06939382Courtesy of FORD MOTOR CO.
  10. Install 2 lower clutch housing-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 10: Locating Lower Clutch Housing-To-Engine Bolts
      G06939383Courtesy of FORD MOTOR CO.
  11. Install the 6 new flexplate-to-clutch nuts. Tighten the nuts in a star pattern in 2 stages.
    NOTE: Rotate the engine in a clockwise direction only or engine damage will occur.
    NOTE: Tighten the flexplate-to-clutch nuts in a star pattern or transaxle damage can occur.
    NOTE: Using a magnetic socket will help ensure ease of installation. If the nuts are dropped in the clutch housing, the transaxle will have to be removed to retrieve them.
    • Stage 1: Tighten nuts 1, 5 and 3 to 12 Nm (106 lb-in).
    • Stage 2: Tighten all nuts to 25 Nm (18 lb-ft).
      Fig 11: Locating Flexplate-To-Clutch Nuts
      G06939384Courtesy of FORD MOTOR CO.
  12. Install the flexplate-to-clutch nut access cover.
    Fig 12: Locating Flexplate-To-Clutch Nut Access Cover
    G06939385Courtesy of FORD MOTOR CO.
  13. Install the 4 lower clutch housing-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 13: Locating Lower Clutch Housing-To-Engine Bolts
      G06939386Courtesy of FORD MOTOR CO.
  14. Install the engine splash shield, if equipped.
    Fig 14: Locating Engine Splash Shield Bolts
    G06939387Courtesy of FORD MOTOR CO.
  15. Using the special tools, lower the transaxle.
    Fig 15: Installing Special Tools And Support Engine
    G06939388Courtesy of FORD MOTOR CO.
  16. Install the transaxle support insulator and install the 2 transaxle support insulator bolts and the 2 nuts.
    • Tighten the 2 bolts to 90 Nm (66 lb-ft).
    • Tighten the 2 nuts to 125 Nm (92 lb-ft).
      Fig 16: Locating Transaxle Support Insulator Bolts And Nuts
      G06939389Courtesy of FORD MOTOR CO.
  17. Install the ground wire and bolt onto the transaxle.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 17: Locating Ground Wire Bolt
      G06939390Courtesy of FORD MOTOR CO.
  18. Install the transaxle roll restrictor and the 2 bolts and tighten in sequence shown in illustration.
    1. Tighten to 70 Nm (52 lb-ft).
    2. Tighten to 70 Nm (52 lb-ft).
      Fig 18: Locating Transaxle Roll Restrictor Bolts
      G06939391Courtesy of FORD MOTOR CO.
  19. Attach the HO2S  electrical connector to the HO2S  bracket.
    Fig 19: Locating HO2S Electrical Connector From HO2S Bracket
    G06939392Courtesy of FORD MOTOR CO.
  20. Using a new exhaust flange gasket, connect the exhaust flange to the exhaust and install the new exhaust flange nuts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 20: Locating Exhaust Flange Nuts
      G06939393Courtesy of FORD MOTOR CO.
  21. Using the LH halfshaft seal protector provided with the new LH halfshaft seal, install the LH halfshaft partially into the transaxle.
    Fig 21: Installing LH Halfshaft Into Transaxle
    G06939394Courtesy of FORD MOTOR CO.
  22. Remove the LH halfshaft seal protector and install the LH halfshaft into the transaxle.
    Fig 22: Installing LH Halfshaft Into Transaxle
    G06939395Courtesy of FORD MOTOR CO.
  23. Install the LH ball joint into the knuckle.
  24. Install the new LH lower control arm knuckle bolt and nut.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 23: Locating LH Lower Control Arm Knuckle Bolt
      G06939396Courtesy of FORD MOTOR CO.
  25. Install the brake hose retainer and bolt on the LH strut.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 24: Locating Brake Hose Retainer Bolt
      G06939397Courtesy of FORD MOTOR CO.
  26. Using the RH halfshaft seal protector provided with the new RH halfshaft seal, install the RH intermediate shaft assembly partially into the transaxle.
    Fig 25: Installing RH Intermediate Shaft Assembly Into Transaxle
    G06939398Courtesy of FORD MOTOR CO.
  27. Remove the RH halfshaft seal protector and install the RH intermediate shaft assembly into the transaxle.
    Fig 26: Installing RH Intermediate Shaft Assembly Into Transaxle
    G06939399Courtesy of FORD MOTOR CO.
  28. Install the new center bearing bracket and new nuts. Tighten the nuts in 2 stages.
    • Stage 1: Tighten to 6 Nm (53 lb-in).
    • Stage 2: Tighten to 25 Nm (18 lb-ft).
      Fig 27: Locating Center Bearing Bracket Nuts
      G06939400Courtesy of FORD MOTOR CO.
  29. Install the RH ball joint into the knuckle.
  30. Install the new RH lower control arm knuckle bolt and nut.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 28: Locating RH Lower Control Arm Knuckle Bolt
      G06939401Courtesy of FORD MOTOR CO.
  31. Install the brake hose retainer and bolt on the RH strut.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 29: Locating Brake Hose Retainer Bolt
      G06939402Courtesy of FORD MOTOR CO.
  32. Install the brake hose retainer and bolt on the RH strut.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 30: Locating Brake Hose Retainer Bolt
      G06939403Courtesy of FORD MOTOR CO.
  33. Install the front wheels. For additional information, refer to WHEELS & TIRES .
  34. Install the starter motor. For additional information, refer to STARTING SYSTEM .
  35. Install the 2 upper clutch housing-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 31: Locating Upper Clutch Housing-To-Engine Bolts
      G06939404Courtesy of FORD MOTOR CO.
  36. Connect the engine harness electrical connector to the TCM  .
    Fig 32: Locating Engine Harness Electrical Connector From Transmission Control Module
    G06939405Courtesy of FORD MOTOR CO.
  37. Install the selector lever cable bracket and the 2 selector lever cable bracket bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 33: Locating Selector Lever Cable Bracket Bolts
      G06939406Courtesy of FORD MOTOR CO.
  38. Attach the wiring harness to the selector lever cable bracket.
    Fig 34: Locating Wiring Harness From Selector Lever Cable Bracket
    G06939407Courtesy of FORD MOTOR CO.
  39. Connect the selector lever cable to the manual control lever.
    Fig 35: Locating Selector Lever Cable From Manual Control Lever
    G06939408Courtesy of FORD MOTOR CO.
  40. Attach the transaxle vent hose to the cooling fan housing.
    Fig 36: Locating Transaxle Vent Hose From Cooling Fan Housing
    G06939409Courtesy of FORD MOTOR CO.
  41. Tighten the upper strut mount nuts.
    NOTE: LH shown in illustration, RH similar.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 37: Locating LH/RH Top Strut Nuts
      G06939410Courtesy of FORD MOTOR CO.
  42. Install the battery tray bracket, battery tray bracket nuts and the selector lever cable bracket bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 38: Locating Selector Lever Cable Bracket Bolt And Battery Tray Bracket Nuts
      G06939411Courtesy of FORD MOTOR CO.
  43. Attach the wiring harness to the battery tray bracket.
    Fig 39: Locating Wiring Harness To Battery Tray Bracket
    G06939412Courtesy of FORD MOTOR CO.
  44. Install the battery tray and 3 battery tray bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 40: Locating Battery Tray Bolts
      G06939413Courtesy of FORD MOTOR CO.
  45. Connect the 3 PCM electrical connectors.
    Fig 41: Locating PCM Electrical Connectors
    G06939414Courtesy of FORD MOTOR CO.
  46. Install the ACL  and the outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING .
  47. Install the cowl assembly. For additional information, refer to FRONT END BODY PANELS .
  48. Install the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  49. Fill the transaxle with transmission fluid. For additional information, refer to TRANSMISSION DRAINING AND FILLING .
  50. Adjust the selector lever cable. For additional information, Refer to AUTOMATIC TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS .
  51. Verify transaxle calibration. For additional information, refer to TRANSMISSION CONTROL MODULE (TCM) ADAPTIVE LEARNING .
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