Transaxle - 3.5L

Illustration	Tool Name	Tool Number
Courtesy of FORD MOTOR CO.	Engine Lifting Bracket	303-1245
Courtesy of FORD MOTOR CO.	Handle	205-153 (T80T-4000-W)
Courtesy of FORD MOTOR CO.	Heat Gun	107-R0300
Courtesy of FORD MOTOR CO.	Installer, Halfshaft	204-161 (T97P-1175-A)
Courtesy of FORD MOTOR CO.	Installer, Halfshaft Oil Seal	308-431
Courtesy of FORD MOTOR CO.	Installer, PTU Drive Gear Outer Oil Seal	308-430
Courtesy of FORD MOTOR CO.	Lifting Bracket, Engine	303-050 (T70P-6000)
Courtesy of FORD MOTOR CO.	Remover/Installer, Bearing Cup	204-038 (T77F-1217-A)
Courtesy of FORD MOTOR CO.	Spreader Bar	303-1246
Courtesy of FORD MOTOR CO.	Support Bar, Engine	303-F072
Courtesy of FORD MOTOR CO.	Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

All vehicles 

1. Prior to installing the transaxle, apply multi-purpose grease to the torque converter pilot hub.
Fig 1: Identifying Torque Converter Pilot Hub
Courtesy of FORD MOTOR CO.
2. Position the transaxle to the back of the engine.
3. Install the 7 transaxle-to-engine bolts.
   • Tighten to 48 Nm (35 lb-ft).
Fig 2: Locating Transaxle-To-Engine Bolts
Courtesy of FORD MOTOR CO.
4. Connect the transmission fluid cooler hoses to the transmission cooler tubes.
Fig 3: Locating Transmission Fluid Cooler Hoses
Courtesy of FORD MOTOR CO.
5. Install 4 new torque converter nuts.
   • Tighten to 36 Nm (27 lb-ft).
Fig 4: Identifying Torque Converter Nuts
Courtesy of FORD MOTOR CO.
6. Position the inspection cover in place and install the 2 fasteners.
Fig 5: Identifying Inspection Cover & Fasteners
Courtesy of FORD MOTOR CO.

All-Wheel Drive (AWD) vehicles 

7. Position the power transfer unit Power Transfer Unit (PTU) in place and install the 5 bolts.
   • Tighten to 90 Nm (66 lb-ft).
Fig 6: Locating PTU Bolts
Courtesy of FORD MOTOR CO.
8. Using the Bearing Cup Remover/Installer and Handle, install a new intermediate shaft seal.
Fig 7: Identifying Intermediate Shaft Seal & Special Tools (204-038, 205-153)
Courtesy of FORD MOTOR CO.
NOTE: Do not overheat (melt) the seal deflector. If the deflector is damaged, a new one must be used.
9. Using the Heat Gun, heat the new seal deflector. Concentrate the heat across the back of the deflector near the white-colored tabs. Install the seal deflector immediately after heating.
   • If necessary, use the PTU Drive Gear Outer Oil Seal Installer and Halfshaft Oil Seal Installer to seat the seal deflector. Make sure the deflector is fully seated and there are no cracks on the face or inner diameter white-colored tab.
   • For an alternate method to heat the seal deflector, place the deflector in boiling water for 3 to 5 minutes. Dry off deflector and install.
   • Make sure the deflector is completely seated all the way around.
Fig 8: Identifying Seal Deflector
Courtesy of FORD MOTOR CO.
10. Position the PTU support bracket in place and install the 5 bolts.
    • Tighten to 70 Nm (52 lb-ft).
Fig 9: Locating Power Transfer Unit (PTU) Support Bracket & Bolts
Courtesy of FORD MOTOR CO.
11. Position the RH catalytic converter in place and install the 4 nuts.
    • Tighten to 40 Nm (30 lb-ft).
Fig 10: Locating RH Catalytic Converter Nuts
Courtesy of FORD MOTOR CO.
12. Install the 2 catalytic converter bracket bolts.
    • Tighten to 20 Nm (177 lb-in).
Fig 11: Identifying Catalytic Converter Bracket Bolts
Courtesy of FORD MOTOR CO.
13. Connect the RH catalyst monitor sensor electrical connector.
Fig 12: Locating RH Catalyst Monitor Electrical Connector
Courtesy of FORD MOTOR CO.
14. Position the driveshaft in place, align the index marks made during removal and install the bolts.
    • Tighten to 70 Nm (52 lb-ft).
Fig 13: Identifying Drive Shaft Bolts
Courtesy of FORD MOTOR CO.
15. Position the RH halfshaft in the transaxle and in the wheel hub and install the 2 bolts.
    • Tighten to 23 Nm (17 lb-ft).
Fig 14: Locating RH Halfshaft Bearing Support Bracket Bolts
Courtesy of FORD MOTOR CO.

Front Wheel Drive (FWD) vehicles 

16. Install the RH halfshaft in the transaxle and install the 3 bolts.
    • Tighten to 55 Nm (41 lb-ft).
Fig 15: Identifying Intermediate Shaft Bearing Support Bracket & Nuts
Courtesy of FORD MOTOR CO.
17. Install the catalytic converter support bracket and install the 2 nuts.
    • Tighten to 23 Nm (17 lb-ft).
Fig 16: Identifying Catalytic Converter Support Bracket & Nuts
Courtesy of FORD MOTOR CO.
18. Install the 2 catalytic converter bracket bolts.
    • Tighten to 20 Nm (177 lb-in).
Fig 17: Identifying Catalytic Converter Bracket Bolts
Courtesy of FORD MOTOR CO.

All vehicles 

NOTE: LH shown, RH similar.
19. Position the subframe in place and install the 2 front subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
Fig 18: Locating Front Subframe Nuts
Courtesy of FORD MOTOR CO.
20. Position the subframe support brackets in place and loosely install the bolts.
Fig 19: Locating Subframe Support Brackets And Bolts
Courtesy of FORD MOTOR CO.
21. Install the rear subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
Fig 20: Locating Rear Subframe Nuts
Courtesy of FORD MOTOR CO.
22. Tighten the subframe support bracket bolts.
    • Tighten to 103 Nm (76 lb-ft).
Fig 21: Locating Subframe Support Brackets And Bolts
Courtesy of FORD MOTOR CO.
23. Position the steering gear in place and install the 3 bolts.
    • Tighten to 107 Nm (79 lb-ft).
Fig 22: Locating Steering Gear Bolts
Courtesy of FORD MOTOR CO.
24. Position the power steering cooler line bracket in place and install the bolts.
    • Tighten to 9 Nm (80 lb-in).
Fig 23: Locating Power Steering Cooler Tube Bolts
Courtesy of FORD MOTOR CO.
25. Install the 2 roll restrictor bracket bolts.
    • Tighten to 90 Nm (66 lb-ft).
Fig 24: Locating Engine Roll Restrictor Bracket Bolts
Courtesy of FORD MOTOR CO.
26. Install the RH damper fork through bolt connecting the fork to the lower control arm.
    • Tighten to 103 Nm (76 lb-ft).
Fig 25: Locating Damper Fork Bolt
Courtesy of FORD MOTOR CO.
27. Position the lower control arms in the knuckle and install the nuts.
    • Tighten to 200 Nm (148 lb-ft).
Fig 26: Locating Front And Rear Lower Control Arm Nuts
Courtesy of FORD MOTOR CO.

AWD vehicles 

28. Using the Halfshaft Installer, install the halfshaft in the wheel hub.
Fig 27: Identifying Special Tool 204-161
Courtesy of FORD MOTOR CO.
29. Install a new front wheel hub nut.
    • Tighten to 255 Nm (185 lb-ft).
Fig 28: Locating Front Wheel Hub Nut
Courtesy of FORD MOTOR CO.

All vehicles 

30. Install the LH halfshaft. For additional information, refer to FRONT DRIVE HALFSHAFTS article.
NOTE: LH shown, RH similar.
31. Position the sway bar links in the struts and install the nuts.
    • Tighten to 40 Nm (30 lb-ft).
Fig 29: Locating Sway Bar Links Nut
Courtesy of FORD MOTOR CO.
32. Position the Y-pipe in place and install the 6 Y-pipe nuts.
    • Tighten to 40 Nm (30 lb-ft).
Fig 30: Locating Y-Pipe Nuts & Y-Pipe Assembly
Courtesy of FORD MOTOR CO.
33. Install the LH front structure to subframe splash shield and install the pin-type retainers.
Fig 31: Locating LH Front Structure-To-Subframe Splash Shield
Courtesy of FORD MOTOR CO.
34. Position the LH fender splash shield in place and install the 4 screws.
Fig 32: Locating LH Fender Splash Shield Screws
Courtesy of FORD MOTOR CO.
35. Position the RH front structure-to-subframe splash shield in place and install the 6 pin-type retainers.
Fig 33: Locating RH Front Structure-To-Subframe Splash Shield
Courtesy of FORD MOTOR CO.
36. Position the RH fender splash shield in place and install the 4 screws.
Fig 34: Locating RH Fender Splash Shield Screws
Courtesy of FORD MOTOR CO.
37. Apply threadlock and sealer to the threads and install the transaxle support insulator bracket, the 2 nuts and the bolt.
    • Tighten to 80 Nm (59 lb-ft).
Fig 35: Locating Transaxle Support Insulator Bracket Nuts & Bolt
Courtesy of FORD MOTOR CO.
38. Using the Engine Support Bar, raise the transaxle. Apply threadlock and sealant to the threads and install the transaxle support insulator through bolt.
    • Tighten to 130 Nm (96 lb-ft).
Fig 36: Identifying Transaxle Support Insulator Through Bolt
Courtesy of FORD MOTOR CO.
39. Remove the Engine Support Bar and Spreader Bar.
Fig 37: Installing Engine Support Bar & Spreader Bar To Support Engine
Courtesy of FORD MOTOR CO.
40. Remove the Engine Lifting Bracket from the LH cylinder head.
Fig 38: Special Tool (303-1245) On LH Cylinder Head
Courtesy of FORD MOTOR CO.
41. Install the 4 upper transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
Fig 39: Identifying Upper Transaxle-To-Engine Bolts
Courtesy of FORD MOTOR CO.
42. Install the starter and the 2 bolts.
    • Tighten to 26 Nm (19 lb-ft).
Fig 40: Locating Starter Bolts
Courtesy of FORD MOTOR CO.
43. Connect the 2 starter motor electrical connectors and position back the electrical terminal cover.
    • Tighten the larger nut to 12 Nm (106 lb-in).
    • Tighten the smaller nut to 5 Nm (44 lb-in).
Fig 41: Identifying Starter Motor Electrical Connectors
Courtesy of FORD MOTOR CO.
44. Position the 2 ground straps in place and install the 2 ground strap bolts.
    • Tighten to 12 Nm (106 lb-in).
Fig 42: Identifying Ground Straps & Ground Strap Bolts
Courtesy of FORD MOTOR CO.
45. Connect the wiring harness fasteners on the torque converter housing stud bolt and the starter motor.
Fig 43: Identifying Wiring Harness Fasteners & Torque Converter Housing Stud Bolt
Courtesy of FORD MOTOR CO.
46. Connect the Transmission Control Module (TCM) electrical connector.
Fig 44: Identifying Transmission Control Module Electrical Connector
Courtesy of FORD MOTOR CO.
47. Position the selector lever cable in place and install the 2 bolts and the nut.
    • Tighten to 12 Nm (106 lb-in).
Fig 45: Identifying Selector Lever Cable Bracket Bolts & Nuts
Courtesy of FORD MOTOR CO.
48. Connect the selector lever cable end.
Fig 46: Locating Selector Lever Cable End
Courtesy of FORD MOTOR CO.
49. Remove the transmission fluid fill plug.
Fig 47: Locating Fluid Fill Plug
Courtesy of FORD MOTOR CO.
50. Fill the transaxle with clean transmission fluid.
51. Install the transmission fluid fill plug.
    • Tighten to 39 Nm (29 lb-ft).
Fig 48: Locating Fluid Fill Plug
Courtesy of FORD MOTOR CO.
52. Install the upper intake manifold. For additional information, refer to ENGINE - 3.5L article.
53. Install the air cleaner and outlet tube. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - 2.3L article or INTAKE AIR DISTRIBUTION AND FILTERING - 3.0L (4V) article.
54. Install the battery tray and the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
55. Remove the transmission fluid level indicator and make sure that the transaxle has transmission fluid in it.
56. With the transaxle in PARK, the vehicle on a level surface, the engine at idle (680-780 RPM) and foot pressed on the brake, move the selector lever through each gear and allow engagement of each gear. Place the selector lever back in the PARK position.
57. Wipe the transmission fluid level indicator cap and remove the transmission fluid level indicator.
58. Wipe the transmission fluid level indicator with a clean cloth.
NOTE: In order to get an accurate transmission fluid level reading the vehicle should be on a level surface. Idle the engine to reach the normal operating temperature. Using the scan tool, verify that the transaxle is at normal operating temperature 60°C-70°C (140°F-158°F), prior to adjusting the transmission fluid level.
59. If transmission fluid needs to be added, add transmission fluid in 0.25L (1/2 pt) increments through the transmission fluid fill plug located on the top of the transaxle near the transmission fluid level indicator. Do not overfill the transmission fluid. Install the transmission fluid level indicator back in the transmission fluid filler tube until it is fully seated, then remove the indicator. The transmission fluid level should be at the upper most mark on the transmission fluid level indicator. Only fill to the upper most mark on the transmission fluid level indicator. Do not overfill. Damage to the transaxle will occur.
Fig 49: Locating Fluid Level Indicator
Courtesy of FORD MOTOR CO.
NOTE: The correct transmission fluid level at normal operating temperature of 60°C-70°C (140°F-158°F) is between the top 2 marks on the transmission fluid level indicator.
60. Fill the transaxle to the correct transmission fluid level.
Fig 50: Locating Temperature Marks On Fluid Level Indicator
Courtesy of FORD MOTOR CO.
NOTE: The correct transmission fluid level at cold operating temperature of 15°C-25°C (59°F-77°F) is at the bottom mark on the transmission fluid level indicator.
61. If the Transmission Fluid Temperature (TFT) is low, fill the transaxle with transmission fluid to the cold range on the transmission fluid level indicator. Recheck the transmission fluid level when the transaxle has reached the normal operating temperature.
Fig 51: Locating Bottom Mark On Fluid Level Indicator
Courtesy of FORD MOTOR CO.