Removal And Installation: Transaxle: Installation

All vehicles 

1. Visual check. Apply the specified lubricant to the specified component.

   Material: Motorcraft® MERCON® LV Automatic Transmission Fluid XT-10-QLVC.

   1. Seal (7D258)
   2. Backing ring (7J324)
2. • Tighten to 9 Nm (80 lb-in).
3. • Tighten to 30 Nm (22 lb-ft).
4. New bolt.
   • Tighten to 9 Nm (80 lb-in).
5. New bolt.
   • Tighten to 9 Nm (80 lb-in).
6. NOTE: Make sure that when installing the manual control lever it is fully seated onto the manual control lever shaft or damage to the manual control lever shaft will occur and the lever will come loose.
   NOTE: Make sure to hold the manual control lever while tightening the manual control lever nut or damage to the manual control lever and park components will occur.
   • Tighten to 18 Nm (159 lb-in).
7. Visual check.
8. Apply the substance from the specified tube.

   Material: Multi-Purpose Grease XG-4 and/or XL-5.

9. NOTE: If the transmission is not positioned on the dowel pins, damage to the transmission can occur.

   Visual check.

10. • Tighten to 48 Nm (35 lb-ft).
11. • Tighten to 48 Nm (35 lb-ft).
12. Special Tool(s): Adapter, Transmission Jack 209-00152.

    General equipment: Transmission jack.

15. NOTE: Use only the specified bolts for the torque converter. Standard length fasteners may bottom out and damage the torque converter clutch apply surface.

    Turn the component CW 120 degrees 3 times.

    Install 3 new torque converter bolts (W714722).

    • Install the first torque converter bolt in the slotted hole on the flexplate.
    • Tighten to 55 Nm (41 lb-ft).

16. AWD vehicles 

17. • Tighten to 90 Nm (66 lb-ft).
18. • Tighten to 70 Nm (52 lb-ft).
19. Install the RH catalytic converter. Refer to EXHAUST SYSTEM .
20. NOTE: Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal.
    • Tighten to 70 Nm (52 lb-ft).

    All vehicles 

21. • Tighten to 90 Nm (66 lb-ft).
22. Install the subframe. Refer to UNI-BODY, SUBFRAME AND MOUNTING SYSTEM .
23. Wire brush. Apply the substance from the specified tube.

    Materials: Threadlock and Sealer TA-25.

    • Tighten to 115 Nm (85 lb-ft).
24. • Tighten to 9 Nm (80 lb-in).
25. Install the exhaust Y-pipe. Refer to EXHAUST SYSTEM .
26. Install the LH halfshaft and the intermediate shaft. Refer to FRONT DRIVE HALFSHAFTS .
27. • Tighten the bolt to 80 Nm (59 lb-ft).
    • Tighten the nuts to 63 Nm (46 lb-ft).
28. • Tighten to 175 Nm (129 lb-ft).
29. Special Tool(s): Support Bar, Engine 303-F072, Bar, Engine Spreader 303-1454.
30. Special Tool(s): Eye, Engine Lift 303-1245.
31. If a new solenoid body was installed, wipe the surface of the existing solenoid body strategy tag on top of the transmission case clean and install the new solenoid body strategy tag (supplied with the solenoid body service kit) over it.
32. • Tighten to 48 Nm (35 lb-ft).
35. NOTE: The fuel tube retainer is damaged when it is removed from the transmission stud and will no longer secure the fuel tubes to the transmission stud. Failure to discard the old fuel tube retainer and install a new fuel tube retainer can result in damage to the fuel tubes.
36. NOTE: Be sure the fuel tubes are installed in the fuel tube retainer in the same position and orientation as noted during removal. The fuel vapor tube is in the top groove of the retainer and the fuel supply tube is in the bottom groove of the retainer. Failure to install the fuel tubes in the correct position and orientation can result in the fuel tubes rubbing on components in the engine compartment causing damage to the fuel tubes.
37. • Tighten to 26 Nm (19 lb-ft).
39. • Tighten to 12 Nm (106 lb-in)
    • Tighten to 6 Nm (53 lb-in).
42. NOTE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket.
    NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable retainer to click in place. Pull back on the selector lever cable to make sure that the selector lever is locked into the selector lever cable bracket.
43. Place the manual control lever in DRIVE.
    1. Rotate the manual control lever clockwise until it stops.
    2. Rotate the manual control lever counterclockwise one detent until it stops.
48. Install the upper intake manifold. Refer to ENGINE - 3.5L .
49. Install the battery tray. Refer to BATTERY, BATTERY MOUNTING & BATTERY CABLES .
50. Install the ACL and ACL outlet pipe. Refer to INTAKE AIR DISTRIBUTION SYSTEM & INTAKE AIR FILTERING SYSTEM .
51. Fill with clean transmission fluid to the correct level. Refer to TRANSMISSION FLUID DRAIN AND REFILL .
52. If a replacement transmission assembly is being installed or a new solenoid body is installed, the PCM will must be reflashed with a new solenoid body strategy and identification data file. Refer to SOLENOID BODY STRATEGY DOWNLOAD .
53. After completing the repairs, perform the Misfire Monitor Neutral Profile Correction procedure.