Transaxle - 3.0L

Illustration	Tool Name	Tool Number
	Engine Lifting Bracket Set	303-1140
	Handle	205-153 (T80T-4000-W)
	Heat Gun	107-R0300
	Installer, Halfshaft	204-161 (T97P-1175-A)
	Installer, Halfshaft Oil Seal	308-431
	Installer, PTU Drive Gear Outer Oil Seal	308-430
	Lifting Bracket, Engine	303-050 (T70P-6000)
	Remover/Installer, Bearing Cup	204-038 (T77F-1217-A)
	Socket, Exhaust Gas Oxygen Sensor	303-476 (T94P-9472-A)
	Support Bar, Engine	303-F072
	Universal Adapter Bracket	014-0001
	Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) 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 5 transaxle-to-engine bolts.
   • Tighten to 40 Nm (30 lb-ft).
Fig 2: Locating Transaxle-To-Engine Bolts
Courtesy of FORD MOTOR CO.
4. Connect the transmission fluid cooler hoses to the transmission fluid cooler tubes.
Fig 3: Locating Transmission Fluid Cooler Hoses
Courtesy of FORD MOTOR CO.
5. Install 3 new torque converter nuts.
   • Tighten to 36 Nm (27 lb-ft).
Fig 4: Locating Torque Converter Nuts
Courtesy of FORD MOTOR CO.
6. Install the inspection cover.
Fig 5: Identifying Inspection Cover
Courtesy of FORD MOTOR CO.
7. Connect the wiring harness fastener to the stud bolt and position the Heated Oxygen Sensor (HO2S) bracket in place and install the bolt.
   • Tighten to 12 Nm (106 lb-in).
Fig 6: Identifying Heated Oxygen Sensor (HO2S) Bracket & Stud Bolt
Courtesy of FORD MOTOR CO.
8. Position the transaxle insulator bracket in place. Apply threadlock and sealer to the threads and install the 2 nuts and the bolt.
   • Tighten to 80 Nm (59 lb-ft).
Fig 7: Locating Transaxle Insulator Bracket Nuts And Bolt
Courtesy of FORD MOTOR CO.
9. Raise the transaxle. Apply threadlock and sealer to the threads and install the 2 transaxle insulator-to-frame bolts.
   • Tighten to 62 Nm (46 lb-ft).
Fig 8: Locating Transaxle Insulator Bolts
Courtesy of FORD MOTOR CO.
10. Remove the Engine Support Bar.
Fig 9: Installing Engine Support Bar To Support Engine
Courtesy of FORD MOTOR CO.
11. Remove the Engine Lifting Bracket and the Universal Adapter Bracket "L" hook from the from the LH side of the engine.
Fig 10: Identifying Universal Lifting Brackets
Courtesy of FORD MOTOR CO.
12. Remove the upper half of the Engine Lifting Bracket Set.
Fig 11: Identifying Upper Half Of Lifting Hook
Courtesy of FORD MOTOR CO.
13. Remove the lower half of the Engine Lifting Bracket Set.
Fig 12: Identifying Lower Half Of Lifting Hook
Courtesy of FORD MOTOR CO.

All-Wheel Drive (AWD) vehicles 

14. Position the Power Transfer Unit (PTU) in place and install the 5 bolts.
    • Tighten to 90 Nm (66 lb-ft).
Fig 13: Locating PTU Bolts
Courtesy of FORD MOTOR CO.
15. Using the Bearing Cup Remover/Installer and Handle, install a new intermediate shaft seal.
Fig 14: 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.
16. 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 15: Identifying Seal Deflector
Courtesy of FORD MOTOR CO.
17. Position the PTU support bracket in place and install the 5 bolts.
    • Tighten to 70 Nm (52 lb-ft).
Fig 16: Identifying PTU Support Bracket Bolts
Courtesy of FORD MOTOR CO.
18. Position the RH catalytic converter in place and install the catalytic converter-to-exhaust manifold nuts.
    • Tighten to 40 Nm (30 lb-ft).
Fig 17: Locating RH Catalytic Converter Nuts
Courtesy of FORD MOTOR CO.
19. Install the catalytic converter band clamp LH half and the 2 bolts.
    • Tighten to 40 Nm (30 lb-ft).
Fig 18: Locating Catalytic Converter Band Clamp LH Half Nuts
Courtesy of FORD MOTOR CO.
20. Install the catalytic converter band clamp RH half and install the 3 nuts.
    • Tighten to 20 Nm (177 lb-in).
Fig 19: Locating RH Exhaust Heat Shield Bracket Nuts - Inboard Half
Courtesy of FORD MOTOR CO.
21. Install the RH exhaust manifold heat shield and the 6 bolts.
    • Tighten to 11 Nm (97 lb-in).
Fig 20: Locating RH Exhaust Heat Shield Bolts
Courtesy of FORD MOTOR CO.
22. Using the Exhaust Gas Oxygen Sensor Socket, install the RH HO2S.
    • Tighten to 48 Nm (35 lb-ft).
Fig 21: Identifying RH HO2S & Special Tool (303-476)
Courtesy of FORD MOTOR CO.
23. Connect the RH HO2S electrical connector.
Fig 22: Identifying RH HO2S Electrical Connector
Courtesy of FORD MOTOR CO.
24. Using the Exhaust Gas Oxygen Sensor Socket, install the RH catalyst monitor sensor.
    • Tighten to 48 Nm (35 lb-ft).
Fig 23: Identifying RH Catalyst Monitor Sensor & Special Tool (303-476)
Courtesy of FORD MOTOR CO.
25. Connect the RH catalyst monitor sensor electrical connector and attach the wiring harness retainer.
Fig 24: Locating RH Catalyst Monitor Sensor Electrical Connector & Wiring Retainer
Courtesy of FORD MOTOR CO.
26. Position the driveshaft in place, align the index marks made during removal and install the 4 driveshaft bolts.
    • Tighten to 70 Nm (52 lb-ft).
Fig 25: Identifying Drive Shaft Bolts
Courtesy of FORD MOTOR CO.
27. Position the RH halfshaft in place and install the 2 RH halfshaft bearing support bracket bolts.
    • Tighten to 23 Nm (17 lb-ft).
Fig 26: Locating RH Halfshaft Bearing Support Bracket Bolts
Courtesy of FORD MOTOR CO.

Front Wheel Drive (FWD) vehicles 

28. Position the RH halfshaft in the transaxle and install the 2 RH halfshaft bearing support bracket bolts.
    • Tighten to 55 Nm (41 lb-ft).
Fig 27: Locating RH Halfshaft Carrier Bearing Bracket Bolts
Courtesy of FORD MOTOR CO.
29. Install the bolt retaining the brake caliper hose.
    • Tighten to 22 Nm (16 lb-ft).
Fig 28: Locating Brake Caliper Hose Bolt
Courtesy of FORD MOTOR CO.
30. Connect the HO2S to the RH halfshaft bearing support bracket.
Fig 29: Locating Heated Oxygen Sensor (HO2S) Electrical Connector
Courtesy of FORD MOTOR CO.
31. Install the catalytic converter-to-engine block bracket and install the 2 bolts.
    • Tighten to 35 Nm (26 lb-ft).
Fig 30: Locating Catalytic Converter-To-Engine Block Bracket And Bolts
Courtesy of FORD MOTOR CO.
32. Install the catalytic converter band clamp and the 2 bolts.
    • Tighten to 20 Nm (177 lb-in).
Fig 31: Locating Catalytic Converter Band Clamp And Bolts
Courtesy of FORD MOTOR CO.
33. Install the RH exhaust manifold heat shield and the 2 bolts.
    • Tighten to 11 Nm (97 lb-in).
Fig 32: Locating RH Exhaust Manifold Heat Shield And Bolts
Courtesy of FORD MOTOR CO.

All vehicles 

NOTE: FWD shown, AWD similar.
34. Loosely install the EGR tube nut on the RH exhaust manifold.
Fig 33: Locating EGR Tube Nut At RH Exhaust Manifold
Courtesy of FORD MOTOR CO.
35. Position the subframe in place using a suitable powertrain lift.
NOTE: LH shown, RH similar.
36. Install the front subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
Fig 34: Locating Front Subframe Nuts
Courtesy of FORD MOTOR CO.
37. Position the subframe support brackets in place and loosely install the bolts.
Fig 35: Locating Subframe Support Brackets And Bolts
Courtesy of FORD MOTOR CO.
38. Install the rear subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
Fig 36: Locating Rear Subframe Nuts
Courtesy of FORD MOTOR CO.
39. Tighten the subframe support bracket bolts.
    • Tighten to 103 Nm (76 lb-ft).
Fig 37: Locating Subframe Support Brackets And Bolts
Courtesy of FORD MOTOR CO.
40. Position the power steering gear in place and install the 3 bolts.
    • Tighten to 107 Nm (79 lb-ft).
Fig 38: Locating Steering Gear Bolts
Courtesy of FORD MOTOR CO.
41. Position the power steering line bracket in place and install the bolts.
    • Tighten to 9 Nm (80 lb-in).
Fig 39: Locating Power Steering Cooler Tube Bolts
Courtesy of FORD MOTOR CO.
NOTE: FWD shown, AWD similar.
42. Install the 2 transaxle roll restrictor bolts.
    • Tighten to 90 Nm (66 lb-ft).
Fig 40: Locating Engine Roll Restrictor Bracket Bolts
Courtesy of FORD MOTOR CO.
43. If equipped, install the roll restrictor heat shield and the bolts.
Fig 41: Locating Heat Shield And Bolts
Courtesy of FORD MOTOR CO.
44. Position the Y-pipe assembly in place and install the 2 exhaust flexible pipe-to-catalytic converter nuts.
    • Tighten to 40 Nm (30 lb-ft).
Fig 42: Locating Flex Pipe Nuts
Courtesy of FORD MOTOR CO.
45. Install the Y-pipe bolts and the Y-pipe nuts.
    • Tighten to 40 Nm (30 lb-ft).
Fig 43: Locating Y-Pipe Bolts And Nuts
Courtesy of FORD MOTOR CO.
46. Install the RH damper fork through bolt connecting the fork to the lower control arm.
    • Tighten to 103 Nm (76 lb-ft).
Fig 44: Locating Damper Fork Bolt
Courtesy of FORD MOTOR CO.
47. Position the lower control arms in the knuckle and install the nuts.
    • Tighten to 200 Nm (148 lb-ft).
Fig 45: Locating Front And Rear Lower Control Arm Nuts
Courtesy of FORD MOTOR CO.

AWD vehicles 

48. Using the Halfshaft Installer, install the LH halfshaft in the wheel hub. For additional information, refer to FRONT DRIVE HALFSHAFTS article.
Fig 46: Identifying Special Tool 204-161
Courtesy of FORD MOTOR CO.
49. Install the RH front wheel hub nut.
    • Tighten 225 Nm (185 lb-ft).
Fig 47: Locating Front Wheel Hub Nut
Courtesy of FORD MOTOR CO.

All vehicles 

NOTE: LH shown, RH similar.
50. Using the Halfshaft Installer, install the RH halfshaft in the wheel hub. For additional information, refer to FRONT DRIVE HALFSHAFTS article.
Fig 48: Identifying Special Tool 204-161
Courtesy of FORD MOTOR CO.
NOTE: LH shown, RH similar.
51. Position the sway bar links in the struts and install the nuts.
    • Tighten to 40 Nm (30 lb-ft).
Fig 49: Locating Sway Bar Links Nut
Courtesy of FORD MOTOR CO.
52. Install the LH front structure to subframe splash shield and install the pin-type retainers.
Fig 50: Locating LH Front Structure-To-Subframe Splash Shield
Courtesy of FORD MOTOR CO.
53. Position the LH fender splash shield in place and install the 4 screws.
Fig 51: Locating LH Fender Splash Shield Screws
Courtesy of FORD MOTOR CO.
54. Position the RH front structure-to-subframe splash shield in place and install the 6 pin-type retainers.
Fig 52: Locating RH Front Structure-To-Subframe Splash Shield
Courtesy of FORD MOTOR CO.
55. Position the RH fender splash shield in place and install the 4 screws.
Fig 53: Locating RH Fender Splash Shield Screws
Courtesy of FORD MOTOR CO.
56. Position the power steering line bracket on the right cylinder head and install the bolt.
    • Tighten to 7 Nm (62 lb-in).
Fig 54: Locating Bracket For Power Steering Hose
Courtesy of FORD MOTOR CO.
57. Install a new gasket and the EGR valve and install the 2 bolts.
    • Tighten to 25 Nm (18 lb-ft).
Fig 55: Locating EGR Valve And Bolts
Courtesy of FORD MOTOR CO.
58. Install the EGR tube on the valve.
    • Tighten to 40 Nm (30 lb-ft).
Fig 56: Locating EGR Tube Nut
Courtesy of FORD MOTOR CO.
59. Connect the EGR valve electrical connector.
Fig 57: Locating EGR Valve Electrical Connector
Courtesy of FORD MOTOR CO.
NOTE: FWD shown, AWD similar.
60. Tighten the EGR tube at the RH exhaust manifold.
    • Tighten to 40 Nm (30 lb-ft).
Fig 58: Locating EGR Tube Nut At RH Exhaust Manifold
Courtesy of FORD MOTOR CO.
61. Install the 3 upper transaxle-to-engine retaining bolts.
    • Tighten to 40 Nm (30 lb-ft).
Fig 59: Locating Upper Torque Converter Housing Bolts
Courtesy of FORD MOTOR CO.
62. Install the starter and the 2 bolts.
    • Tighten to 26 Nm (19 lb-ft).
Fig 60: Locating Starter Bolts
Courtesy of FORD MOTOR CO.
63. Connect the 2 starter motor electrical connectors.
    • Tighten the larger nut to 12 Nm (106 lb-in).
    • Tighten the smaller nut to 5 Nm (44 lb-in).
Fig 61: Identifying Starter Motor Electrical Connectors
Courtesy of FORD MOTOR CO.
64. Install the electrical cover for the starter motor electrical connectors.
Fig 62: Identifying Electrical Cover For Starter Motor Electrical Connectors
Courtesy of FORD MOTOR CO.
65. Install the 2 ground wires and ground wire bolts.
    • Tighten to 12 Nm (106 lb-in).
Fig 63: Identifying Ground Straps & Ground Strap Bolts
Courtesy of FORD MOTOR CO.
66. Connect the Transmission Control Module (TCM) electrical connector.
Fig 64: Identifying Transmission Control Module Electrical Connector
Courtesy of FORD MOTOR CO.
67. Position the selector lever cable and bracket in place and install the selector lever cable nut and 2 selector lever cable bolts.
    • Tighten to 12 Nm (106 lb-in).
Fig 65: Locating Transaxle Control Cable Bracket Bolts
Courtesy of FORD MOTOR CO.
68. Connect the selector lever cable end.
Fig 66: Locating Selector Lever Cable End
Courtesy of FORD MOTOR CO.
69. Remove the transmission fluid fill plug.
Fig 67: Locating Fluid Fill Plug
Courtesy of FORD MOTOR CO.
70. Fill the transaxle with clean transmission fluid.
71. Install the transmission fluid fill plug.
    • Tighten to 39 Nm (29 lb-ft).
Fig 68: Locating Fluid Fill Plug
Courtesy of FORD MOTOR CO.
72. 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.
73. Install the battery tray and the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
74. Remove the transmission fluid level indicator and make sure that the transaxle has transmission fluid in it.
75. 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.
76. Wipe the transmission fluid level indicator cap and remove the transmission fluid level indicator.
77. 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.
78. 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 transmission fluid level 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 69: 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 fluid level indicator.
79. Fill the transaxle to the correct fluid level.
Fig 70: 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.
80. 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 71: Locating Bottom Mark On Fluid Level Indicator
Courtesy of FORD MOTOR CO.