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Home >> Ford >> 2012 >> Explorer Base, 3.5 8, AWD, 6F50 >> Repair and Diagnosis >> External Pages >> Different car >> Section 212 (Engine Mechanical - 3.7L Ti-VCT) >> Removal And Installation >> Engine - All Wheel Drive (AWD) >> Installation

Engine - All Wheel Drive (AWD): Installation

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  1. Using the Floor Crane and Spreader Bar, align the transaxle to the engine.
    G09065953
  2. Align the transaxle to the engine and install the 5 transaxle-to-engine bolts.
    G09065954
    • Tighten to 48 Nm (35 lb-ft).
  3. Install the 2 engine-to-transaxle bolts.
    • Tighten to 48 Nm (35 lb-ft).
      G09065955
  4. Install the RH halfshaft support bracket and the 2 bolts.
    • Tighten to 40 Nm (30 lb-ft).
      G09065956
  5. Install the 2 intermediate shaft bracket studs and nuts.
    • Tighten the studs to 10 Nm (89 lb-in).
    • Tighten the nuts to 25 Nm (18 lb-ft).
      G09065957
  6. NOTE: LH shown in illustration, RH similar.

    Install the ratchet strap from the front subframe to the LH engine lift eye and from the rear of the subframe to the RH engine lift eye.

    G09065958
  7. Using the Floor Crane and Spreader Bar, install the powertrain and subframe as an assembly on the powertrain lift table.
    G09065959
  8. NOTE: LH shown in illustration, RH similar.

    Remove the ratchet strap from the front subframe to the LH engine lift eye and from the rear of the subframe to the RH engine lift eye.

    G09065960
  9. Install the Adjustable Grip Arm.
    G09065961
  10. Install a ratchet strap from the front of the subframe under the powertrain lift table to the rear of the subframe, to secure the subframe to the powertrain lift table.
  11. Position the PTU  support bracket in place and install the 5 bolts.
    • Tighten to 70 Nm (52 lb-ft).
      G09065962
  12. Install 6 new RH exhaust manifold studs.
    • Tighten to 12 Nm (106 lb-in).
      G09065963
  13. NOTE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.

    Using a new gasket, install the RH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown in illustration:

    • Stage 1: Tighten to 20 Nm (177 lb-in).
    • Stage 2: Tighten to 25 Nm (18 lb-ft).
      G09065964
  14. Install the RH catalytic converter heat shield, Catalyst Monitor Sensor (CMS) wiring harness bracket and the 4 bolts.
    • Tighten to 10 Nm (89 lb-in).
      G09065965
  15. Connect the RH Heated Oxygen Sensor (HO2S) electrical connector.
    G09065966
  16. Connect the RH CMS  electrical connector.
    G09065967
  17. Attach the transaxle control wire harness retainer to the transaxle stud bolt.
    G09065968
  18. Connect the transaxle control electrical connector.
    G09065969
  19. Position the wiring harness and attach the 3 wiring harness retainer to the valve cover stud bolt.
    G09065970
  20. Connect the generator B+ cable and install the nut.
    • Tighten to 17 Nm (150 lb-in).
      G09065971
  21. Position back the generator B+ cable cover and connect the generator electrical connector.
    G09065972
  22. Connect the 2 A/C compressor electrical connectors.
    • Attach the A/C wiring harness retainer.
      G09065973
  23. Install the ground wire to the RH cylinder head and install the bolt.
    • Tighten to 10 nm (89 lb-In).
      G09065974
  24. Install the starter and the stud bolts.
    • Tighten to 27 Nm (20 lb-ft).
      G09065975
  25. Connect the wiring harness retainer to the starter motor stud bolt.
    G09065976
  26. Attach the starter wire terminals and install the 2 nuts.
    • Tighten the B+ terminal nut to 12 Nm (106 lb-in).
    • Tighten the S-terminal nut to 5 Nm (44 lb-in).
      G09065977
  27. Install the starter motor solenoid cover.
    G09065978
  28. Remove the Heavy Duty Floor Crane and Spreader Bar.
    G09065979
  29. Remove 303-1245 from the LH cylinder head.
    G09065980
  30. Raise the subframe and powertrain assembly into the vehicle.
  31. Install the engine mount, the 3 bolts and the 4 engine mount nuts hand tight.
    • Tighten the 3 engine mount bolts to 90 Nm (66 lb-ft).
    • Tighten the 4 engine mount nuts to 63 Nm (46 lb-ft).
      G09065981
  32. Install the transaxle support insulator assembly the 3 nuts and the bolt.
    • Tighten the nuts to 63 Nm (46 lb-ft).
    • Tighten the bolt to 80 Nm (59 lb-ft).
      G09065982
  33. Install the 4 transmission support insulator-to-frame rail bolts.
    • Tighten the 2 bottom bolts to 55 Nm (41 lb-ft).
    • Tighten the 2 top bolts to 70 Nm (52 lb-ft).
      G09065983
  34. NOTE: RH shown in illustration, LH similar.

    Align the subframe and install the new front subframe bolts.

    • Tighten to 200 Nm (148 lb-ft).
      G09065984
  35. NOTE: RH shown in illustration, LH similar.

    Install the rear subframe brackets and the new subframe bracket-to-body bolts.

    • Finger tight at this stage.
      G09065985
  36. NOTE: RH shown in illustration, LH similar.

    Install the new subframe bracket bolts.

    • Tighten to 150 Nm (111 lb-ft).
      G09065986
  37. NOTE: RH shown in illustration, LH similar.

    Tighten the subframe bracket-to-body bolts to 55 Nm (41 lb-ft).

    G09065987
  38. Remove the ratchet strap from the front of the subframe to the rear of the subframe.
  39. Remove the Adjustable Grip Arm and the powertrain lift table.
    G09065988
  40. NOTE: LH shown in illustration, RH similar.

    Install the strut to the wheel knuckle and install the strut-to-wheel knuckle nuts and bolts.

    • Tighten to 250 Nm (184 lb-ft).
      G09065989
  41. NOTE: LH shown in illustration, RH similar.

    Install the brake caliper and the guide pin bolts.

    • 432 mm (17 in) brakes: Tighten to 72 Nm (53 lb-ft).
    • 457 mm (18 in) brakes: Tighten to 75 Nm (55 lb-ft).
      G09065990
  42. NOTE: Do not tighten the wheel hub nut with the vehicle on the ground. The nut must be tightened to specification before the vehicle is lowered onto the wheels. Wheel bearing damage will occur if the wheel bearing is loaded with the weight of the vehicle applied.
    NOTE: LH shown in illustration, RH similar.
    NOTE: Apply the brake to keep the halfshaft from rotating.

    Using the previously removed wheel hub nut, seat the LH and RH halfshafts.

    • Tighten to 350 Nm (258 lb-ft).
    • Remove and discard the wheel hub nuts.
      G09065991
  43. NOTE: The wheel hub nut contains a one time locking chemical that is activated by the heat created when it is tightened. Install and tighten the new wheel hub nut to specification within 5 minutes of starting it on the threads. Always install a new wheel hub nut after loosening or when not tightened within the specified time or damage to the components can occur.
    NOTE: LH shown in illustration, RH similar.
    NOTE: Apply the brake to keep the halfshaft from rotating.

    Install a new wheel hub nuts.

    • Tighten to 350 Nm (258 lb-ft).
      G09065992
  44. NOTE: LH shown in illustration, RH similar.

    Install the new upper stabilizer link nut.

    • Tighten to 150 Nm (111 lb-ft).
      G09065993
  45. NOTE: LH shown in illustration, RH similar.

    Install the wheel speed sensor and the bolt.

    • Tighten to 15 Nm (133 lb-in).
      G09065994
  46. Connect the transaxle cooler tubes and install the 2 secondary latches.
    G09065995
  47. Install the oil cooler hose retainer to the subframe.
    G09065996
  48. Connect the oil cooler coolant hoses.
    G09065997
  49. Connect the 2 PTU  cooler hoses. For additional infomation, REFER to QUICK CONNECT COUPLING .
    G09065998
  50. Install the 4 oil pan-to-transaxle bolts.
    • Tighten to 48 Nm (35 lb-ft).
      G09065999
  51. Install 3 new torque converter bolts by rotating the crankshaft clockwise.
    • Tighten to 55 Nm (41 lb-ft).
      G09066000
  52. Install the inspection cover and the 2 fasteners.
    G09066001
  53. NOTE: Do not lubricate the engine oil filter gasket.

    Install a new engine oil filter.

    • Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
      G09066002
  54. Line up the index marks on the rear driveshaft to the index marks on the PTU  flange made during removal and install the 4 new bolts.
    • Tighten to 70 Nm (52 lb-ft).
      G09066003
  55. Install the exhaust Y-pipe. For additional information, Refer to EXHAUST Y-PIPE - 3.5L TI-VCT .
  56. NOTE: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring may occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to CLOCKSPRING , and CLOCKSPRING ADJUSTMENT .

    Align and connect the steering column shaft to the steering gear and install the bolt.

    • Tighten to 20 Nm (177 lb-in).
      G09066004
  57. If equipped, attach the engine block heater harness to the radiator support.
  58. Connect the transaxle control cable to the shift cable bracket.
    G09066005
  59. Connect the transaxle control cable to the control lever.
    G09066006
  60. Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.
    G09066007
  61. Install the ground cable and the bolt to the RH strut tower.
    • Tighten to 10 Nm (89 lb-in).
      G09066008
  62. Install the engine wiring harness retainer to the bulkhead.
    1. Slide the wiring harness in the bulkhead.
    2. Make sure the wiring harness retainer tab is below the bulkhead lip.
      G09066009
  63. Connect the engine harness electrical connector.
    • Attach the wiring harness retainer.
      G09066010
  64. Connect the 2 PCM  electrical connectors.
    G09066011
  65. Connect the EVAP  tube and the fuel supply tube quick connect couplings. REFER to QUICK CONNECT COUPLING .
    G09066012
  66. Connect the brake booster vacuum hose to the upper intake manifold.
    G09066013
  67. Connect the degas bottle coolant hose to the engine coolant tube.
    G09066014
  68. Install the degas bottle. REFER to DEGAS BOTTLE .
  69. Using a new O-ring seal and gasket seal, install the A/C tube and the nut.
    • Tighten to 15 Nm (133 lb-in).
      G09066015
  70. Connect the A/C pressure switch electrical connector.
    G09066016
  71. Using a new O-ring seal and gasket seal, connect the A/C tube and install the nut.
    • Tighten to 15 Nm (133 lb-in).
      G09066017
  72. Install the accessory drive belt. REFER to ACCESSORY DRIVE BELT - 3.5L TI-VCT, 3.7L TI-VCT .
  73. NOTE: RH shown in illustration, LH similar.

    Install the 2 RH and 2 LH lower pin-type retainers for the engine splash shields.

    G09066018
  74. Install the front wheels and tires. REFER to WHEEL AND TIRE .
  75. Connect the engine wiring harness electrical connector.
    G09066019
  76. Install the ground wire and the stud bolt.
    • Tighten to 10 Nm (89 lb-in).
      G09066020
  77. Connect the nut to the ground wire attached to the body.
    • Tighten to 10 Nm (89 lb-in).
      G09066021
  78. Connect the 2 battery feed cables from the positive battery terminal and install the nut.
    • Tighten to 9 Nm (80 lb-in).
      G09066022
  79. Install the battery tray. REFER to BATTERY AND BATTERY TRAY - EXPLODED VIEW .
  80. Install the engine ACL  and ACL  outlet pipe. REFER to INTAKE AIR SYSTEM COMPONENTS - EXPLODED VIEW .
  81. Install the cowl panel. REFER to COWL PANEL .
  82. Fill the engine with clean engine oil.
  83. Fill and bleed the cooling system. REFER to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
  84. Recharge the A/C system. REFER to AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING .
  85. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.
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