Section 35 (Manual Transmission - 6-Speed Manual Transmission - Tr3160): Installation: Transmission

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For information on Ford Color Coded Illustrations refer to OEM COLOR CODING

Materials

Name	Specification
Motorcraft® Premium Long-Life GreaseXG-1-E1	ESA-M1C75-B
Motorcraft® MERCON® LV Automatic Transmission FluidXT-10-QLVC	WSS-M2C938-AMERCON® LV,

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.

Clean the input shaft and apply a small amount of grease to the splined surface and the pilot bearing surface.
Material: Motorcraft® Premium Long-Life Grease / XG-1-E1 (ESA-M1C75-B)

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Install the clutch housing bolts in the correct location as noted during removal.
1. 60 mm Studbolt
  Torque: 35 lb.ft (48 Nm)
2. 60 mm Studbolt
  Torque: 35 lb.ft (48 Nm)
3. 80 mm Studbolt
  Torque: 35 lb.ft (48 Nm)
4. 60 mm StudBolt
  Torque: 35 lb.ft (48 Nm)
5. 60 mm Bolt
  Torque: 35 lb.ft (48 Nm)
6. 60 mm Bolt
  Torque: 35 lb.ft (48 Nm)
7. 75 mm Bolt
  Torque: 35 lb.ft (48 Nm)
8. 25 mm Bolt
  Torque: 35 lb.ft (48 Nm)
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Connect the clutch master cylinder tube and install the retainer.

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Install the vent tube.

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Connect the electrical connectors and the wiring harness retainers.

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Install the wiring harness and the nut on the studbolt.
Torque: 115 lb.in (13 Nm)

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Inspect the transmission mounted transmission fluid cooler tube backer rings and seals for damage and install new backer rings or seals if necessary.
1. Backer ring (7J324)
2. Seal (7D285)
  Material: Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV,)
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Install the transmission fluid cooler tubes, bolts and nuts.
Torque: 1: 35 lb.ft (48 Nm) 2: 124 lb.in (14 Nm) 3: 89 lb.in (10 Nm)

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Install the LH catalyst monitor sensor. Refer to: Catalyst Monitor Sensor
Install the RH catalytic converter. Refer to: Catalytic Converter RH
Install the starter motor. Refer to: Starter Motor
Install the transmission support insulator and crossmember and the bolts.
Torque: 76 lb.ft (103 Nm)

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Install the gearshift lever. Refer to: Gearshift Lever .
Install the upper RH catalytic converter nut.
Torque: 30 lb.ft (40 Nm)

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Fill the transmission. Refer to: Transmission Draining and Filling
Connect the battery. Refer to: Battery Disconnect and Connect
Fill and bleed the clutch hydraulic system. Refer to: Clutch System Bleeding