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Transaxle - All Wheel Drive (AWD): Installation

WARNING: This page is about a different car, the 2006 Mercury Montego, 2006 Ford Freestyle, and 2006 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION:
  1. MERCON®, MERCON® V, MERCON® SP, Motorcraft Premium Automatic Transmission Fluid and Motorcraft Continuously Variable Chain Type Transmission Fluid are not interchangeable transmission fluids. The use of any fluid other than what is recommended for this transaxle will cause transaxle damage.
  2. If a new transaxle or a mechatronic main control valve body assembly is installed, the transmission control module (TCM) will need to be reflashed to the latest level calibration available. If the TCM is not reflashed, the wrench light on the dash may illuminate and internal transaxle damage may occur.
NOTE: If the transaxle was overhauled or if installing a new transaxle and the transmission fluid cooler tubes have not been flushed, flush the transmission fluid cooler tubes at this time. For additional information, refer to TRANSMISSION FLUID COOLER TUBES - BACKFLUSHING AND CLEANING .

If the transaxle was overhauled or if installing a new transaxle and a new transmission fluid cooler has not been installed, install a new transmission fluid cooler at this time. For additional information, refer to REMOVAL AND INSTALLATION .

  1. If installing a new transaxle, install the transmission fluid level indicator, tube and the bolt.
    • Tighten to 10 N.m (89 lb-in).
    Fig 1: Locating Transmission Fluid Level Indicator, Tube & Bolt
    G04657030Courtesy of FORD MOTOR CO.
  2. If installing a new transaxle, install the transaxle insulator using new retainers.
    Fig 2: Locating Transaxle Insulator Retainers
    G04657031Courtesy of FORD MOTOR CO.
  3. If removed, clean the rear transaxle mount bolts using a wire brush and apply new threadlock to the threads.
  4. If installing a new transaxle, install the rear transaxle support insulator.
    • Tighten to 55 N.m (41 lb-ft).
    Fig 3: Locating Rear Transaxle Support Insulator Bolts
    G04657032Courtesy of FORD MOTOR CO.
  5. Prior to installing the original or a new transaxle, apply multi-purpose grease to the torque converter pilot hub.
    Fig 4: Locating Torque Converter Pilot Hub
    G04657033Courtesy of FORD MOTOR CO.
  6. Position the transaxle to the back of the engine.
  7. Install the 3 transaxle-to-engine retaining bolts.
    • Tighten to 40 N.m (30 lb-ft).
    Fig 5: Locating Transaxle-To-Engine Retaining Bolts
    G04657034Courtesy of FORD MOTOR CO.
  8. Install 4 new transmission fluid cooler tube seals.
    Fig 6: Locating Transmission Fluid Cooler Tube Seals
    G04657035Courtesy of FORD MOTOR CO.
    9. CAUTION: Make sure that when installing the transmission fluid cooler tubes they are installed straight, or damage to the transmission fluid cooler tubes will occur.
    Fig 7: Locating Transmission Fluid Cooler Tubes
    G04657036Courtesy of FORD MOTOR CO.
  9. Connect the transmission fluid cooler tubes to the transaxle.
    • Tighten to 10 N.m (89 lb-in).
  10. Position the transmission fluid cooler tubes in place and install the bolts.
    • Tighten to 10 N.m (89 lb-in).
    Fig 8: Locating Transmission Fluid Cooler Tubes Bolts
    G04657037Courtesy of FORD MOTOR CO.
  11. Install 4 new torque converter retaining nuts.
    • Tighten to 36 N.m (27 lb-ft).
    Fig 9: Locating Torque Converter Retaining Nuts
    G04657038Courtesy of FORD MOTOR CO.
  12. Install the lower rubber access plug and install the retaining pin.
    Fig 10: Locating Lower Rubber Access Plug
    G04657039Courtesy of FORD MOTOR CO.
  13. Position the catalytic converter is place and loosely install the bolt for the bracket.
    Fig 11: Locating Bracket Bolt
    G04657040Courtesy of FORD MOTOR CO.
  14. Connect the heated oxygen sensor (HO2S) electrical connector.
    Fig 12: Locating Heated Oxygen Sensor (HO2S) Electrical Connector
    G04657041Courtesy of FORD MOTOR CO.
  15. Using a suitable powertrain lift, position the subframe in place and install the 4 bolts.
    • Tighten to 90 N.m (66 lb-ft).
    Fig 13: Locating Subframe Bolts
    G04657042Courtesy of FORD MOTOR CO.
  16. Install the 2 bolts for the LH rear subframe mount.
    • Tighten to 48 N.m (35 lb-ft).
    Fig 14: Locating LH Rear Subframe Mount Bolts
    G04657043Courtesy of FORD MOTOR CO.
  17. Install the 2 bolts for the RH rear subframe mount.
    • Tighten to 48 N.m (35 lb-ft).
    Fig 15: Locating RH Rear Subframe Mount Bolts
    G04657044Courtesy of FORD MOTOR CO.
  18. Install the 2 bolts for the rear transaxle mount.
    • Tighten to 90 N.m (66 lb-ft).
    Fig 16: Locating Rear Transaxle Mount Bolts
    G04657045Courtesy of FORD MOTOR CO.
  19. Install the nut for the rear motor mount.
    • Tighten to 70 N.m (52 lb-ft).
    Fig 17: Locating Rear Motor Mount Nut
    G04657046Courtesy of FORD MOTOR CO.
  20. Install the 2 bolts for the lower stabilizer mount.
    • Tighten to 70 N.m (52 lb-ft).
    Fig 18: Locating Lower Stabilizer Mount Bolts
    G04657047Courtesy of FORD MOTOR CO.
  21. Install the nut for the front motor mount.
    • Tighten to 70 N.m (52 lb-ft).
    Fig 19: Locating Front Motor Mount Nut
    G04657048Courtesy of FORD MOTOR CO.
  22. Position the splash shield in place and install the 3 pushpins.
    Fig 20: Locating Splash Shield Pushpins
    G04657049Courtesy of FORD MOTOR CO.
  23. Connect the HO2S electrical connector to the subframe.
    Fig 21: Locating HO2S Electrical Connector
    G04657050Courtesy of FORD MOTOR CO.
  24. Position the power steering rack in place. Install the bolts and nuts.
    • Tighten to 133 N.m (98 lb-ft).
    Fig 22: Locating Power Steering Rack Bolt & Nut
    G04657051Courtesy of FORD MOTOR CO.
  25. Position the power steering line in place and install the 4 bolts.
    • Tighten to 7 N.m (62 lb-in).
    Fig 23: Locating Power Steering Line Bolt
    G04657052Courtesy of FORD MOTOR CO.
  26. Connect the wire harness to the LH front subframe.
    Fig 24: Locating Wire Harness
    G04657053Courtesy of FORD MOTOR CO.
  27. Position the lower radiator hose in place and connect the retainers.
    Fig 25: Locating Lower Radiator Hose
    G04657054Courtesy of FORD MOTOR CO.
  28. Install the LH and RH stabilizer bar link into the struts and install new nuts.
    • Tighten to 55 N.m (41 lb-ft).
    Fig 26: Locating Stabilizer Bar Link Nut
    G04657055Courtesy of FORD MOTOR CO.
  29. Remove the special tool from the lifting hook near the EGR valve.
    Fig 27: Identifying Special Tools (303-1140, 303-290A-12)
    G04657056Courtesy of FORD MOTOR CO.
  30. Remove the special tools from the RH (rear) cylinder head.
    Fig 28: Identifying Special Tools (134-00243, 303-290A-12)
    G04657057Courtesy of FORD MOTOR CO.
  31. Remove the special tools from the LH (front) cylinder head.
    Fig 29: Identifying Special Tools (134-00243, 303-290A-12)
    G04657058Courtesy of FORD MOTOR CO.
  32. Remove the special tools.
    Fig 30: Identifying Special Tools (303-290-01, 303-290A, 303-290A-03A, 303-290A-12)
    G04657059Courtesy of FORD MOTOR CO.
  33. Install new bolts for the catalytic converter.
    • Tighten to 40 N.m (30 lb-ft).
    Fig 31: Locating Catalytic Converter Bolts
    G04657060Courtesy of FORD MOTOR CO.
  34. Remove the upper half of the lifting hook.
    Fig 32: Identifying Special Tool (303-1140)
    G04657061Courtesy of FORD MOTOR CO.
  35. Remove the lower half of the lifting hook.
    Fig 33: Locating Lower Half Of Lifting Hook On Special Tool (303-1140)
    G04657062Courtesy of FORD MOTOR CO.
  36. Install the transaxle-to-engine bolt.
    • Tighten to 40 N.m (30 lb-ft).
    Fig 34: Locating Transaxle-To-Engine Bolt
    G04657063Courtesy of FORD MOTOR CO.
  37. Connect the knock sensor wire harness to the transaxle.
    Fig 35: Locating Knock Sensor Wire Harness
    G04657064Courtesy of FORD MOTOR CO.
  38. Install the knock sensor.
    • Tighten to 10 N.m (89 lb-in).
    Fig 36: Locating Knock Sensor Bolt
    G04657065Courtesy of FORD MOTOR CO.
  39. Install the heat shield over the knock sensor.
    Fig 37: Locating Heat Shield
    G04657066Courtesy of FORD MOTOR CO.
  40. If equipped, connect the engine block heater.
    Fig 38: Locating Engine Block Heater
    G04657067Courtesy of FORD MOTOR CO.
  41. Position the power steering hose in place and install the bolt.
    • Tighten to 7 N.m (62 lb-in).
    Fig 39: Locating Power Steering Hose Bolt
    G04657068Courtesy of FORD MOTOR CO.
  42. Tighten the catalytic converter bolt to the bracket.
    • Tighten to 40 N.m (30 lb-ft).
    Fig 40: Locating Bracket Bolt
    G04657069Courtesy of FORD MOTOR CO.
  43. Wipe off any residual grease or contaminants from the power transfer unit (PTU) splines.
    • Apply a thin, uniform coating of constant velocity joint grease to all of the PTU spline surfaces before assembly.
  44. Position the PTU and the rear driveshaft in place and install the 4 bolts.
    • Tighten to 90 N.m (66 lb-ft).
    Fig 41: Locating PTU Bolts
    G04657070Courtesy of FORD MOTOR CO.
  45. Install the upper PTU bracket and the bolts.
    • Tighten to 55 N.m (41 lb-ft).
    Fig 42: Locating Upper PTU Bracket Bolts
    G04657071Courtesy of FORD MOTOR CO.
  46. Install the LH and RH half shafts. For additional information, refer to INSTALLATION - LH and INSTALLATION - RH .
  47. Install the driveshaft cross brace.
    • Tighten to 30 N.m (22 lb-ft).
    Fig 43: Locating Driveshaft Cross Brace Bolts
    G04657072Courtesy of FORD MOTOR CO.
    48. NOTE:
    1. Align the index marks made during removal.
    2. Use a crisscross pattern to tighten the bolts.
    Fig 44: Locating Driveshaft Flange Bolts
    G04657073Courtesy of FORD MOTOR CO.
  48. Using new bolts, install the driveshaft flange.
    • Tighten to 25 N.m (18 lb-ft).
  49. Position the exhaust crossover pipe and install 2 new bolts for the catalytic converter and connect the rubber hanger.
    • Tighten to 40 N.m (30 lb-ft).
    Fig 45: Locating Exhaust Crossover Pipe Bolts
    G04657074Courtesy of FORD MOTOR CO.
  50. Install 2 new nuts for the rear exhaust pipe.
    • Tighten to 40 N.m (30 lb-ft).
    Fig 46: Locating Rear Exhaust Pipe Nuts
    G04657075Courtesy of FORD MOTOR CO.
  51. Install 2 new nuts for the front exhaust pipe.
    • Tighten to 40 N.m (30 lb-ft).
    Fig 47: Locating Front Exhaust Pipe Nuts
    G04657076Courtesy of FORD MOTOR CO.
  52. Install the 4 upper transaxle bolts.
    • Tighten to 40 N.m (30 lb-ft).
    Fig 48: Locating Upper Transaxle Bolts
    G04657077Courtesy of FORD MOTOR CO.
  53. Install the bolt for the power steering line.
    • Tighten to 7 N.m (62 lb-in).
    Fig 49: Locating Power Steering Line Bolt
    G04657078Courtesy of FORD MOTOR CO.
  54. Connect the vapor tube to the canister purge valve.
    Fig 50: Locating Canister Purge Valve
    G04657079Courtesy of FORD MOTOR CO.
  55. Install the PCV hose.
    Fig 51: Locating PCV Hose
    G04657080Courtesy of FORD MOTOR CO.
  56. Connect the vacuum hose to the throttle body.
    Fig 52: Locating Vacuum Hose
    G04657081Courtesy of FORD MOTOR CO.
  57. Position the bracket for the power steering hose and install the bolt.
    • Tighten to 7 N.m (62 lb-in).
    Fig 53: Locating Power Steering Hose Bracket Bolt
    G04657082Courtesy of FORD MOTOR CO.
  58. Install the fluid cooler tube bracket to the transaxle.
    • Tighten to 10 N.m (89 lb-in).
    Fig 54: Locating Fluid Cooler Tube Bracket Bolt
    G04657083Courtesy of FORD MOTOR CO.
  59. Connect the ground wire.
    • Tighten to 12 N.m (9 lb-ft).
    Fig 55: Locating Ground Wire
    G04657084Courtesy of FORD MOTOR CO.
  60. Connect the wire harness to the transaxle.
    Fig 56: Locating Wire Harness
    G04657085Courtesy of FORD MOTOR CO.
    61. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
    Fig 57: Locating Transaxle Bulkhead Electrical Connector
    G04657086Courtesy of FORD MOTOR CO.
  61. Connect the transaxle bulkhead electrical connector.
  62. Install the starter motor.
    • Tighten to 26 N.m (19 lb-ft).
    Fig 58: Locating Starter Motor Bolts
    G04657087Courtesy of FORD MOTOR CO.
  63. Connect the 2 starter motor electrical connectors.
    • Tighten the larger nut to 12 N.m (9 lb-ft).
    • Tighten the smaller nut to 5 N.m (44 lb-in).
    Fig 59: Locating Starter Motor Electrical Connectors (1 Of 2)
    G04657088Courtesy of FORD MOTOR CO.
  64. Install the electrical cover for the starter motor electrical connectors.
    Fig 60: Locating Starter Motor Electrical Connectors (2 Of 2)
    G04657089Courtesy of FORD MOTOR CO.
  65. Clean the roll restrictor bolts using a wire brush and apply new threadlock to the threads.
  66. Position the roll restrictor in place and install the bolts and connect the wire harness to the roll restrictor.
    • Tighten to 40 N.m (30 lb-ft).
    Fig 61: Locating Roll Restrictor
    G04657090Courtesy of FORD MOTOR CO.
  67. Clean the 4 roll restrictor bracket bolts using a wire brush and apply new threadlock to the threads.
  68. Install the roll restrictor bracket and the bolts.
    • Tighten to 40 N.m (30 lb-ft).
    Fig 62: Locating Roll Restrictor Bracket Bolts
    G04657091Courtesy of FORD MOTOR CO.
  69. Connect the lower wire harness to the transaxle.
    Fig 63: Locating Lower Wire Harness
    G04657092Courtesy of FORD MOTOR CO.
  70. If equipped, install the auxiliary coolant flow pump assembly.
    1. Tighten to 7 N.m (62 lb-in).
    2. Connect the electrical connector.
    Fig 64: Identifying Auxiliary Coolant Flow Pump Assembly
    G04657093Courtesy of FORD MOTOR CO.
  71. Connect the wire harness to the transaxle.
    Fig 65: Locating Wire Harness
    G04657094Courtesy of FORD MOTOR CO.
  72. Install the shift cable bracket and bolts.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 66: Locating Shift Cable Bracket Bolts
    G04657095Courtesy of FORD MOTOR CO.
  73. Connect the electrical connector to the shift cable bracket.
    Fig 67: Locating Electrical Connector
    G04657096Courtesy of FORD MOTOR CO.
  74. Connect the shift cable end.
    Fig 68: Locating Shift Cable End
    G04657097Courtesy of FORD MOTOR CO.
  75. Clean the 4 roll restrictor brace bolts using a wire brush and apply new threadlock to the threads.
  76. Position the roll restrictor brace in place and install the 4 bolts.
    • Tighten to 40 N.m (30 lb-ft).
    Fig 69: Locating Roll Restrictor Brace Bolts
    G04657098Courtesy of FORD MOTOR CO.
  77. Clean the upper roll restrictor bolt using a wire brush and apply new threadlock to the threads.
  78. Install the upper roll restrictor bolt.
    • Tighten to 48 N.m (35 lb-ft).
    Fig 70: Locating Upper Roll Restrictor Bolt
    G04657099Courtesy of FORD MOTOR CO.
  79. Install the cowl panel grille. For additional information, refer to REMOVAL AND INSTALLATION .
  80. Install the air cleaner and outlet tube. For additional information, refer to REMOVAL AND INSTALLATION .
  81. Install the battery tray and the battery. For additional information, refer to REMOVAL AND INSTALLATION .
  82. If required, fill the transaxle with clean continuously variable transaxle (CVT) transmission fluid. Use the transmission fluid level setting procedure to fill the transaxle. For additional information, refer to TRANSMISSION FLUID LEVEL CHECK AND SETTING .
  83. If a new transaxle or a mechatronic main control valve body assembly is installed, the TCM will need to be reflashed to the latest level calibration available. If the TCM is not reflashed, the wrench light on the dash may illuminate and internal transaxle damage may occur.
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