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Section 123 (Manual Transaxle/Transmission - Tr6060): Installation: Transmission: Installation

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WARNING: Do not breathe dust or use compressed air to blow dust from storage containers or friction components. Remove dust using government-approved techniques. Friction component dust may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure to follow these instructions may result in serious personal injury.
  1. If necessary, install the cooler tube on the transmission.
    • Tighten to 11 Nm (97 lb-in).
      G08645299
  2. If removed, install the gearshift lever assembly.
    1. Position the gearshift assembly on the transmission.
    2. Install the gearshift assembly bolt.
      • Tighten to 40 Nm (30 lb-ft).
    3. Position the gearshift lever assembly retainers. Rotate the gearshift lever retainers to lock the clips.
      Fig 1: Gearshift Assembly, Bolt And Retainer With Torque Specifications
      G06384474Courtesy of FORD MOTOR CO.
  3. NOTE: Before installing the transmission, clean and lubricate the input shaft with a small amount of grease.
    NOTE: When installing the transmission with the gearshift lever attached, position the gear shifter into NEUTRAL position, so that the shifter will not damage the shift boot.

    Position the transmission at a 45-degree angle, slide the input shaft into the pressure plate and rotate the transmission counterclockwise 45 degrees to align with the dowels.

    • Connect the wiring harness clip to the top of the transmission.
  4. Install the 6 transmission-to-engine bolts and the transmission-to-engine stud bolt.
    • Tighten to 48 Nm (35 lb-ft).
  5. Connect the cooler tube to the transmission cooler tube.
    G08645513
  6. Install the cooler tube secondary latch.
    G08645294
  7. Connect the cooler tube to the transmission connector.
    G08645296
  8. Install the cooler tube bracket nut.
    • Tighten to 48 Nm (35 lb-ft).
      G08645293
  9. Install the 2 engine spacer plate-to-transmission bolts.
    • Tighten to 35 Nm (26 lb-ft).
      Fig 2: Locating Engine Spacer Plate-To-Transmission Bolts
      G07488662Courtesy of FORD MOTOR CO.
  10. Connect the clutch slave cylinder tube to the clutch slave cylinder connector.
    • Attach the clutch hydraulic tube clip.
      Fig 3: Locating Clutch Slave Cylinder Tube And Clip
      G06384310Courtesy of FORD MOTOR CO.
  11. Connect the wiring harness to the RH side of the transmission.
    • Connect the OSS sensor electrical connector.
    • Connect the reverse lamp switch electrical connector.
    • Connect the 2 wiring harness clips.
  12. Connect the wiring harness to the LH side of the transmission.
    • Connect the reverse lockout solenoid electrical connector.
    • Connect the 2 wiring harness clips.
  13. Install the wiring harness retaining nut.
    • Tighten to 12 Nm (106 lb-in).
      Fig 4: Locating Wiring Harness Retaining Nut
      G07488920Courtesy of FORD MOTOR CO.
  14. Using the adjustable jackstands, raise the subframe to the marked position.
    Fig 5: Lifting Subframe Using Adjustable Jackstands
    G07488669Courtesy of FORD MOTOR CO.
  15. NOTE: LH shown, RH similar.

    Install the 4 rear subframe bolts.

    • Tighten to 115 Nm (85 lb-ft).
      Fig 6: Locating Rear Subframe Bolts
      G06393285Courtesy of FORD MOTOR CO.
  16. NOTE: LH shown, RH similar.

    Tighten the 4 front subframe nuts.

    • Tighten to 115 Nm (85 lb-ft).
      Fig 7: Locating Front Subframe Nuts
      G06393284Courtesy of FORD MOTOR CO.
  17. Connect the steering column shaft and install the new steering column shaft pinch bolt.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 8: Locating Steering Column Shaft And Pinch Bolt
      G07488668Courtesy of FORD MOTOR CO.
  18. Install the transmission crossmember. Refer to UNI-BODY, SUBFRAME AND MOUNTING SYSTEM .
  19. Install the 2 gearshift lever nuts.
    • Tighten to 11 Nm (97 lb-in).
      Fig 9: Locating Gearshift Lever Nuts
      G06384303Courtesy of FORD MOTOR CO.
  20. Install the starter motor. Refer to STARTING SYSTEM .
  21. Install the subframe cross brace and the 4 subframe cross brace nuts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 10: Locating Subframe Cross Brace
      G06382494Courtesy of FORD MOTOR CO.
  22. NOTE: Align the index marks on the driveshaft flange and pinion flange, and the driveshaft flange and transmission output shaft flange.

    Install the driveshaft. Refer to DRIVESHAFT .

  23. Install the crossmember brace and 6 crossmember brace bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 11: Locating Crossmember Brace Bolts
      G08645526Courtesy of FORD MOTOR CO.
  24. Tighten the 2 crossmember brace nuts to 48 Nm (35 lb-ft).
    Fig 12: Locating Crossmember Brace Nuts
    G08645527Courtesy of FORD MOTOR CO.
  25. If equipped, install the lower air deflector and install the 9 screws.
    Fig 13: Locating Lower Air Deflector Mounting Screws
    G06395449Courtesy of FORD MOTOR CO.
  26. NOTE: The use of any other transmission fluid than specified can result in the transmission failing to operate in a normal manner or transmission failure.

    Check, and as necessary, fill the transmission with transmission fluid. Apply threadlock and sealer to the fill plug threads and install the fill plug.

    • Tighten to 25 Nm (18 lb-ft).
  27. Install the catalytic converter assembly (H-pipe). Refer to EXHAUST SYSTEM .
  28. Install the 2 dash boot bearing nuts.
    • Tighten to 9 Nm (80 lb-in).
      Fig 14: Locating Dash Boot Bearing Nuts
      G06394907Courtesy of FORD MOTOR CO.
  29. Install the upper gearshift lever and the upper gearshift lever bolts.
    • Tighten to 35 Nm (26 lb-ft).
      Fig 15: Locating Upper Gearshift Lever Bolts
      G07488897Courtesy of FORD MOTOR CO.
  30. Install the floor console finish panel.
    Fig 16: Locating Floor Console Finish Panel
    G07488906Courtesy of FORD MOTOR CO.
  31. If equipped, install the strut tower cross brace and 4 nuts.
    • Tighten to 35 Nm (26 lb-ft).
      Fig 17: Locating Strut Tower Cross Brace And Nuts
      G06382235Courtesy of FORD MOTOR CO.
  32. Connect the battery ground cable. Refer to BATTERY, MOUNTING AND CABLES .
  33. Fill the transmission with the correct fluid level. Refer to TRANSMISSION DRAINING AND FILLING .
  34. WARNING: Carefully read cautionary information on product label. For emergency medical information seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury.
    NOTE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.

    Fill the brake and clutch reservoir. Bleed the clutch hydraulic system. Refer to MANUAL TRANSAXLE/TRANSMISSION AND CLUTCH - GENERAL INFORMATION .

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