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Home >> Ford >> 2012 >> Explorer Limited, 3.5 8, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 222 (Engine Mechanical -3.5L Ti-VCT) >> Removal And Installation >> Engine - All Wheel Drive (AWD) >> Installation

Engine - All Wheel Drive (AWD): Installation

WARNING: This page is about a different car, the 2013 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.
  1. Using the Floor Crane and Spreader Bar, align the transaxle to the engine.
    G08621935
  2. Align the transaxle to the engine and install the 5 transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
      G08621960
  3. Install the 2 engine-to-transaxle bolts.
    • Tighten to 48 Nm (35 lb-ft).
      G08621959
  4. Install the RH halfshaft support bracket and the 2 bolts.
    • Tighten to 40 Nm (30 lb-ft).
      G08621958
  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).
      G08621957
  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.

    G08621954
  7. Using the Floor Crane and Spreader Bar, install the powertrain and subframe as an assembly on the powertrain lift table.
    G08621935
  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.

    G08621954
  9. Install the Adjustable Grip Arm.
    G08621925
  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).
      G08621794
  12. Install 6 new RH exhaust manifold studs.
    • Tighten to 12 Nm (106 lb-in).
      G08616457
  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).
      G08616458
  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).
      G09086270
  15. Connect the RH Heated Oxygen Sensor (HO2S) electrical connector.
    G08616452
  16. Connect the RH CMS  electrical connector.
    G08616451
  17. Attach the transaxle control wire harness retainer to the transaxle stud bolt.
    G08621946
  18. Connect the transaxle control electrical connector.
    G08621945
  19. Position the wiring harness and attach the 3 wiring harness retainer to the valve cover stud bolt.
    G08621944
  20. Connect the generator B+ cable and install the nut.
    • Tighten to 17 Nm (150 lb-in).
      G08029351
  21. Position back the generator B+ cable cover and connect the generator electrical connector.
    G08029350
  22. Connect the 2 A/C compressor electrical connectors.
    • Attach the A/C wiring harness retainer.
      G08029348
  23. Install the ground wire to the RH cylinder head and install the bolt.
    • Tighten to 10 nm (89 lb-In).
      G08621940
  24. Install the starter and the stud bolts.
    • Tighten to 27 Nm (20 lb-ft).
      G08621939
  25. Connect the wiring harness retainer to the starter motor stud bolt.
    G08621938
  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).
      G08621937
  27. Install the starter motor solenoid cover.
    G08616026
  28. Remove the Heavy Duty Floor Crane and Spreader Bar.
    G08621935
  29. Remove 303-1245 from the LH cylinder head.
    G08621934
  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).
      G08029547
  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).
      G09065583
  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).
      G09065582
  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).
      G08622494
  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.
      G08622495
  36. NOTE: RH shown in illustration, LH similar.

    Install the new subframe bracket bolts.

    • Tighten to 150 Nm (111 lb-ft).
      G08622496
  37. NOTE: RH shown in illustration, LH similar.

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

    G08622497
  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.
    G08621925
  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).
      G08621926
  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).
      G08622500
  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.
      G08617108
  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).
      G08621922
  44. NOTE: LH shown in illustration, RH similar.

    Install the new upper stabilizer link nut.

    • Tighten to 150 Nm (111 lb-ft).
      G08622503
  45. NOTE: LH shown in illustration, RH similar.

    Install the wheel speed sensor and the bolt.

    • Tighten to 15 Nm (133 lb-in).
      G08621918
  46. Connect the transaxle cooler tubes and install the 2 secondary latches.
    G08621916
  47. If equipped, install the oil cooler hose retainer to the subframe.
    G08621915
  48. If equipped, connect the oil cooler coolant hoses.
    G08621914
  49. If equipped, connect the 2 PTU  cooler hoses. For additional infomation, refer to FUEL SYSTEM - GENERAL INFORMATION .
    G09065568
  50. Install the 4 oil pan-to-transaxle bolts.
    • Tighten to 48 Nm (35 lb-ft).
      G08621819
  51. Install 3 new torque converter bolts by rotating the crankshaft clockwise.
    • Tighten to 55 Nm (41 lb-ft).
      G08621912
  52. Install the inspection cover and the 2 fasteners.
    G08621798
  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.
      G08029503
  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).
      G08616341
  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).
      G08622513
  57. Install the underbody air duct and the 3 twist lock retainers.
    G07430766
  58. If equipped, attach the engine block heater harness to the radiator support.
  59. Connect the transaxle control cable to the shift cable bracket.
    G08621990
  60. Connect the transaxle control cable to the control lever.
    G08412443
  61. Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.
    G08621903
  62. Install the ground wire to the RH shock tower and install the bolt.
    • Tighten to 10 Nm (89 lb-in).
      G08621902
  63. Install the engine wiring harness retainer to the bulkhead.
    • Slide the wiring harness in the bulkhead.
    • Make sure the wiring harness retainer tab is below the bulkhead lip.
      G08622518
  64. Connect the engine harness electrical connector.
    • Attach the wiring harness retainer.
      G08621900
  65. Connect the 2 PCM  electrical connectors.
    G08621899
  66. Connect the EVAP  tube and the fuel supply tube quick connect coupling. REFER to SPRING LOCK COUPLINGS .
    G08621898
  67. Connect the brake booster vacuum hose to the upper intake manifold.
    G08621897
  68. Connect the degas bottle coolant hose to the engine coolant tube.
    G08028962
  69. Install the degas bottle. REFER to DEGAS BOTTLE .
  70. Using a new O-ring seal and gasket seal, install the A/C tube and the nut.
    • Tighten to 15 Nm (133 lb-in).
      G08029077
  71. Connect the A/C pressure switch electrical connector.
    G08621894
  72. 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).
      G08621655
  73. Install the accessory drive belt. REFER to ACCESSORY DRIVE BELT - 3.5L TI-VCT, 3.7L TI-VCT .
  74. NOTE: RH shown in illustration, LH similar.

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

    G09065549
  75. Install the front wheels and tires. REFER to WHEEL AND TIRE .
  76. Connect the engine wiring harness electrical connector.
    G08621890
  77. Install the ground wire and install the retainer.
    • Tighten to 10 Nm (89 lb-in).
      G09065547
  78. Install the ground wire and the retainer.
    • Tighten to 10 Nm (89 lb-in).
      G08621889
  79. Connect the 2 battery feed cables to the positive battery terminal and install the nut.
    • Tighten to 5 Nm (44 lb-in).
      G08621888
  80. Install the battery tray. REFER to BATTERY AND BATTERY TRAY - EXPLODED VIEW .
  81. Install the engine ACL  and ACL  outlet pipe. REFER to INTAKE AIR SYSTEM COMPONENTS - EXPLODED VIEW .
  82. Install the cowl panel. REFER to COWL PANEL .
  83. Fill the engine with clean engine oil.
  84. Fill and bleed the cooling system. REFER to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
  85. Recharge the A/C system. REFER to AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING .
  86. Perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.
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