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Removal And Installation: Transaxle: Material

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MATERIAL SPECIFICATIONS

Item Specification
Motorcraft® MERCON® LV Automatic Transmission Fluid XT-10-QLV MERCON® LV
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

All vehicles 

    NOTE: Due to packaging requirements, the correct bolt must be used at the damper locations.
    NOTE: The damper contains a clutch which is designed to slip briefly during vehicle operation. It is essential that no grease, oil or cleaning solvents be allowed to contaminate the slip clutch. Do not use grease on transmission input shaft. Should the damper become contaminated, it must be replaced.
    Fig 1: Locating Transaxle Damper Bolts
    G06097936Courtesy of FORD MOTOR CO.
  1. Install the transaxle damper.
    • Tighten to 29 Nm (21 lb-ft).
  2. NOTE: When positioning the engine to the transaxle, care must be taken to maintain alignment of the damper spline with the transaxle input shaft.
    NOTE: Transaxle removed from view for clarity.
    NOTE: If installing a new transaxle, install the lower insulator bracket and bolts.
    • Tighten to 90 Nm (66 lb-ft).

    Using the Heavy Duty Floor Crane and Spreader Bar, position the engine and transaxle together. Install the 6 transaxle-to-engine bolts.

    • Tighten to 48 Nm (35 lb-ft).
    Fig 2: Locating Engine Transaxle Bolts
    G06097942Courtesy of FORD MOTOR CO.
  3. Connect the high voltage wiring harness electrical connector.
    Fig 3: Locating High Voltage Wiring Harness Electrical Connector
    G06097935Courtesy of FORD MOTOR CO.
  4. Using the Heavy Duty Floor Crane and Spreader Bar, position the engine and transaxle onto the Powertrain Lift.
    5. NOTE: Due to the weight of the transaxle, special care should be taken to mount the powertrain securely to the Powertrain Lift.
    Fig 4: Lifting Engine
    G06095071Courtesy of FORD MOTOR CO.
  5. Using the Universal Adapter Brackets, secure the engine to the Powertrain Lift.
  6. Raise the engine and transaxle into the vehicle.
  7. Install the upper insulator.
    1. Tighten the nuts to 90 Nm (66 lb-ft).
    2. Tighten the through bolt to 103 Nm (76 lb-ft).
    Fig 5: Locating Upper Insulator Nuts
    G06097861Courtesy of FORD MOTOR CO.
  8. Install the upper insulator bracket.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 6: Locating Upper Insulator Bracket
    G06097860Courtesy of FORD MOTOR CO.
  9. Install the 3 engine mount bracket nuts.
    • Tighten to 115 Nm (85 lb-ft).
    Fig 7: Locating Engine Mount Bracket Nuts
    G06095073Courtesy of FORD MOTOR CO.
  10. Install the engine mount bracket bolt.
    • Tighten to 115 Nm (85 lb-ft).
    Fig 8: Locating Engine Mount Bracket Bolt
    G06095072Courtesy of FORD MOTOR CO.
  11. Using the Powertrain Lift, raise the subframe into position.
    Fig 9: Raising Subframe Into Position
    G06097949Courtesy of FORD MOTOR CO.
    12. NOTE: RH shown, LH similar.
    Fig 10: Locating Subframe Nuts
    G06097927Courtesy of FORD MOTOR CO.
  12. Install the 2 subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
    13. NOTE: When installing the subframe bolts, make sure both of the subframe bolts are fully engaged in their cage nuts before tightening to specification.
    NOTE: RH shown, LH similar.
    Fig 11: Locating Subframe Bolts
    G06097926Courtesy of FORD MOTOR CO.
  13. Tighten the 2 subframe bolts.
    • Tighten to 175 Nm (129 lb-ft).
  14. Install the rear roll restrictor, bracket and bolts.
    • Tighten to 55 Nm (41 lb-ft).
    Fig 12: Locating Rear Roll Restrictor, Bracket And Bolts
    G06097925Courtesy of FORD MOTOR CO.
  15. Connect the steering column coupling to the steering gear and install the new steering column coupling pinch bolt.
    • Tighten to 40 Nm (30 lb-ft).
    Fig 13: Locating Steering Column Coupling Pinch Bolt
    G06097924Courtesy of FORD MOTOR CO.
  16. Install the rear insulator.
    Fig 14: Locating Rear Insulator
    G06097873Courtesy of FORD MOTOR CO.
  17. Install the 2 rear insulator studs.
    • Tighten to 12 Nm (106 lb-in).
    Fig 15: Locating Rear Insulator Studs
    G06097872Courtesy of FORD MOTOR CO.
  18. Install the 2 rear insulator nuts and 1 rear insulator bolt.
    • Tighten nuts and bolt to 80 Nm (59 lb-ft).
    Fig 16: Locating Rear Insulator Nuts And Rear Insulator Bolt
    G06097871Courtesy of FORD MOTOR CO.
  19. Install the rear insulator through bolt.
    • Tighten to 115 Nm (85 lb-ft).
    Fig 17: Locating Rear Insulator Through Bolt
    G06097870Courtesy of FORD MOTOR CO.
  20. Install the 2 transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
    Fig 18: Identifying Transaxle-To-Engine Bolts
    G06097921Courtesy of FORD MOTOR CO.
  21. Install the 2 transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
    Fig 19: Identifying Transaxle-To-Engine Bolts
    G06097920Courtesy of FORD MOTOR CO.
  22. Install the engine support crossmember.
    • Tighten the 2 bolts to 90 Nm (66 lb-ft).
    • Tighten the new nut to 175 Nm (129 lb-ft).
    Fig 20: Identifying Engine Support Crossmember Nut And Bolts
    G06097867Courtesy of FORD MOTOR CO.
  23. Install the rear roll restrictor-to-crossmember through bolt.
    • Tighten to 90 Nm (66 lb-ft).
    Fig 21: Identifying Rear Roll Restrictor Bolt
    G06097866Courtesy of FORD MOTOR CO.
  24. Install the lower insulator through bolt.
    • Tighten to 115 Nm (85 lb-ft).
    Fig 22: Locating Lower Insulator Through Bolt
    G06097865Courtesy of FORD MOTOR CO.
  25. Connect the lower radiator hose to the radiator.
    Fig 23: Locating Lower Radiator Hose Radiator
    G06095061Courtesy of FORD MOTOR CO.
  26. Install the A/C compressor and connect the A/C compressor electrical connector.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 24: Locating A/C Compressor Electrical Connector
    G06097914Courtesy of FORD MOTOR CO.
  27. Install the auxiliary coolant pump and connect the electrical connector.
    • Tighten to 10 Nm (89 lb-in).
    Fig 25: Locating Auxiliary Coolant Pump Electrical Connector
    G06097915Courtesy of FORD MOTOR CO.
  28. Position the MECS pump and the ground strap. Install the 2 bolts.
    • Tighten to 20 Nm (177 lb-in).
    Fig 26: Locating MECS Pump And Ground Strap Bolts
    G06097913Courtesy of FORD MOTOR CO.
  29. Connect the MECS pump electrical connector and attach the harness retainer.
    Fig 27: Locating MECS Pump Electrical Connector
    G06097912Courtesy of FORD MOTOR CO.
  30. Install the wiring harness fasteners, the transaxle ground cable and nut.
    • Tighten to 20 Nm (177 lb-in).
    Fig 28: Locating Harness Fasteners, Nut And Ground Cable
    G06097911Courtesy of FORD MOTOR CO.
  31. Connect the selector lever cable.
    • Install the selector lever cable bracket and the 2 nuts finger-tight.
    • Attach the selector lever cable to the manual control lever.
    Fig 29: Identifying Selector Lever Cable Bracket And Nuts
    G06097910Courtesy of FORD MOTOR CO.
  32. Position the control lever between the 2 casting ribs on the transaxle case.
    Fig 30: Identifying Control Lever Position
    G06097970Courtesy of FORD MOTOR CO.
  33. Place the gear selector lever in the D position.
  34. Tighten the selector lever cable bracket nuts to 23 Nm (17 lb-ft).
  35. To verify the correct selector lever cable adjustment, observe the selector lever on the transaxle while an assistant moves the selector lever into each range position ending in the D position.
  36. Install the transaxle control snow shield.
    • Tighten to 22 Nm (16 lb-ft).
    Fig 31: Locating Bolts And Transaxle Control Snow Shield
    G06097909Courtesy of FORD MOTOR CO.
    37. NOTE: If installing a new transaxle, tighten transaxle coolant tube fittings to 50 Nm (37 lb-ft).
    Fig 32: Identifying Transaxle Coolant Hoses
    G06097908Courtesy of FORD MOTOR CO.
  37. Connect the transaxle coolant hoses.
  38. Connect the transaxle coolant temperature sensor electrical connector and pin-type retainer.
    Fig 33: Locating Transaxle Coolant Temperature Sensor Electrical Connector
    G06097907Courtesy of FORD MOTOR CO.
  39. Position the DC-to-DC converter in place and install the 3 nuts.
    • Tighten to 12 Nm (106 lb-in).
    Fig 34: Identifying DC-To-DC Converter
    G06097974Courtesy of FORD MOTOR CO.
  40. Connect the DC-to-DC converter electrical connector and 2 wire harness retainer (1 shown).
    Fig 35: Locating DC-To-DC Converter Electrical Connector And Wiring Harness Retainers
    G06097905Courtesy of FORD MOTOR CO.
  41. Connect the coolant vent hose.
    Fig 36: Locating Coolant Vent Hose
    G06097904Courtesy of FORD MOTOR CO.
  42. Connect the 2 low voltage electrical connectors and the engine harness-to-body harness retainer.
    Fig 37: Locating Low Voltage Electrical Connectors And Engine Harness-To-Body Harness Retainer
    G06097903Courtesy of FORD MOTOR CO.
  43. Connect the transaxle harness electrical connector and install the stud bolt.
    • Tighten to 10 Nm (89 lb-in).
    Fig 38: Locating Transaxle Harness Electrical Connector
    G06097852Courtesy of FORD MOTOR CO.
  44. Connect the selector lever cable fastener to the intake manifold.
    Fig 39: Locating Selector Lever Cable Fastener
    G06097901Courtesy of FORD MOTOR CO.
  45. Install the selector lever cable fasteners on the transaxle stud bolts.
    Fig 40: Locating Selector Lever Cable Fasteners On Transaxle Stud Bolts
    G06097900Courtesy of FORD MOTOR CO.
  46. Connect the upper Evaporative Emission (EVAP) tube quick connect coupling to the purge valve. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
    Fig 41: Locating Upper Evaporative Emission Tube Quick Connect Coupling
    G06097899Courtesy of FORD MOTOR CO.
  47. Connect the engine control harness electrical connector.
    Fig 42: Locating Engine Control Harness Electrical Connector
    G06095058Courtesy of FORD MOTOR CO.
  48. If equipped, connect the block heater electrical connector.
    • Attach the harness retainer clips.
    Fig 43: Locating Block Heater Electrical Connector
    G06095050Courtesy of FORD MOTOR CO.
  49. Connect the PCM electrical connector.
    • Position the harness and install the nut.
    • Tighten to 6 Nm (53 lb-in).
    Fig 44: Locating PCM Center Electrical Connector
    G06095057Courtesy of FORD MOTOR CO.
  50. Connect the brake booster vacuum hose to the brake booster.
    Fig 45: Locating Brake Booster Vacuum Tube
    G06097895Courtesy of FORD MOTOR CO.
  51. Connect the upper radiator coolant hose.
    Fig 46: Locating Upper Radiator Coolant Hose
    G06097986Courtesy of FORD MOTOR CO.
  52. Connect the heater hoses to the heater core.
    Fig 47: Locating Heater Hoses Clamp
    G06097893Courtesy of FORD MOTOR CO.

    All-Wheel Drive (AWD) vehicles 

  53. Position the Power Transfer Unit (PTU) in place and install the 4 bolts.
    • Tighten to 45 Nm (33 lb-ft).
    Fig 48: Identifying Transfer Case-To-Transaxle Bolts And Transfer Case
    G06097892Courtesy of FORD MOTOR CO.
  54. Connect the PTU vent hose.
    Fig 49: Locating Transfer Case Vent Hose
    G06097891Courtesy of FORD MOTOR CO.
  55. Install the PTU heat shield and the bolts.
    • Tighten to 14 Nm (124 lb-in).
    Fig 50: Locating PTU Heat Shield And Bolts
    G06097990Courtesy of FORD MOTOR CO.
  56. Position the PTU-to-engine support bracket and install the bolts.
    • Tighten to 40 Nm (30 lb-ft).
    Fig 51: Locating Bolts And Transfer Case-To-Engine Bracket
    G06097889Courtesy of FORD MOTOR CO.
  57. Install the exhaust bracket bolts.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 52: Locating Exhaust Bracket Bolts
    G06097888Courtesy of FORD MOTOR CO.
  58. Install the driveshaft. For additional information, refer to DRIVESHAFT .

    All vehicles 

  59. Install the LH halfshaft and intermediate shaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
    60. NOTE: RH side shown, LH similar.
    Fig 53: Identifying Stabilizer Bar Link And Nut
    G06097993Courtesy of FORD MOTOR CO.
  60. Connect the RH and LH suspension.
    1. Position the tie-rod end and install the retaining nut.
      • Tighten to 55 Nm (41 lb-ft).
    2. Connect the stabilizer bar link and install the nut.
      • Tighten to 63 Nm (46 lb-ft).
  61. Install the RH brake hose retainer and the ABS sensor bolt.
    • Tighten to 15 Nm (133 lb-in).
    Fig 54: Locating Brake Hose Retainer And ABS Sensor Retaining Bolt
    G06097885Courtesy of FORD MOTOR CO.
  62. Install the LH brake hose retainer and the ABS sensor bolt.
    • Tighten to 15 Nm (133 lb-in).
    Fig 55: Locating Brake Hose Retainer And ABS Sensor Retaining Bolt
    G06097883Courtesy of FORD MOTOR CO.
  63. Install the catalytic converter inlet pipe and install the nuts.
    Fig 56: Identifying Catalytic Converter Inlet Pipe-To-Catalytic Manifold Converter Nuts
    G06097882Courtesy of FORD MOTOR CO.
  64. Remove the catalytic converter inlet pipe-to-converter nuts.
    Fig 57: Locating Catalytic Converter Inlet Pipe-To-Converter Nuts
    G06097881Courtesy of FORD MOTOR CO.
  65. Install the lateral support crossmember and the bolts.
    • Tighten to 115 Nm (85 lb-ft).
    Fig 58: Identifying Lateral Support Crossmember And Bolts
    G06095031Courtesy of FORD MOTOR CO.
  66. Install the front wheels and tires. For additional information, refer to WHEELS & TIRES .
  67. Connect the fuel supply tube. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
    Fig 59: Locating Fuel Supply Tube
    G06097879Courtesy of FORD MOTOR CO.
  68. Install the accessory drive belt. For additional information, refer to ACCESSORY DRIVE - HYBRID .
  69. Install the engine coolant degas bottle. For additional information, refer to ENGINE COOLING - HYBRID .
  70. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  71. Install the engine ACL. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING - HYBRID .
  72. Enable the vehicle high voltage electrical system. For additional information, refer to HIGH VOLTAGE TRACTION BATTERY .
  73. Reset the Passive Anti-Theft System (PATS). For additional information, refer to ANTI-THEFT - PATS - HYBRID .
  74. Fill and bleed the motor electronics cooling system. For additional information, refer to TRANSAXLE/TRANSMISSION COOLING - HYBRID .
  75. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING - HYBRID .
  76. Fill the transaxle. For additional information, refer to TRANSMISSION FLUID DRAIN AND REFILL .
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