Removal & Installation: Transaxle: Installation

Secure the transmission using a retaining strap and move into installation position using a transmission jack. Tighten the lower transaxle flange bolts and install the catalytic converter support bracket. See TORQUE SPECIFICATIONS . Install the starter motor lower bolt and tighten to specification. See Figure .
Remove the wooden block. See Figure . Lower the vehicle. Using the 3 Bar Engine Support (303-290) and Adapters (303-290-01 and 303-290-03), raise the engine and transaxle into engine compartment. Raise and support the vehicle.
Install front roll restrictor and tighten bolts to specification. See Figure . See TORQUE SPECIFICATIONS . Install right and left side lower suspension arm ball joint pinch bolts and tighten to specification.
Install the accessory drive belt splash shield. Install the gearshift and selector cable fittings to the gearshift and selector lever. See Figure . Install the gearshift and selector cable to the bracket by turning the lower part of abutment clockwise and the upper part counter clockwise.
Fill the transaxle to proper level with appropriate fluid. See SERVICING - M/T article in MANUAL TRANSMISSIONS. Close the cover on the gearshift and selector cables. Install the catalytic converter assembly.
Tighten the upper transaxle flange bolts, starter motor bolt and ground lead bolt to specification. See TORQUE SPECIFICATIONS . Using 3 bar engine support bar and adapters, raise the engine and transaxle until it becomes possible to install the rear engine mount.
Install the rear engine mount bracket. See Figure . Install the rear engine mount. See Figure . Install the gearshift cable bracket mounting. Remove the 3 bar engine support bar and adapters.
Connect the reverse light switch harness connector. See Figure . Connect the VSS harness connector. See Figure . Connect the vacuum hoses. Connect the brake servo vacuum hose.
Install the clutch slave cylinder high-pressure line and insert the clutch slave cylinder high-pressure line into the bracket. Bleed the clutch hydraulic system. See BLEEDING HYDRAULIC SYSTEM .
Connect the MAF sensor harness connector. Install the intake pipe. Install battery tray. Attach the wiring harness to battery tray. See Figure . Tighten the battery tray bolts. Attach clip to battery tray. Install the battery and connect the positive battery cable.
Using an Allen key to prevent the piston rod from rotating, tighten the left and right side suspension strut nuts to specification. See TORQUE SPECIFICATIONS .
Adjust the gearshift cables. See SERVICING - M/T article in MANUAL TRANSMISSIONS. Connect the negative battery cable.
Carry out a road test to enable the Powertrain Control Module (PCM) to collect data. Check the routing of the vacuum hoses and wiring and secure them with cable ties. Check fluid levels after the road test and correct as necessary. Check the engine and cooling system for leaks (visual inspection).

Using suitable securing straps, secure the transaxle on a transmission jack and install the transaxle. Install the left side transaxle flange bolts and tighten to specification. See TORQUE SPECIFICATIONS . Remove the transmission jack.
Remove the retaining straps from the transaxle. Install the right side transaxle flange bolts and tighten to specification. See TORQUE SPECIFICATIONS . Attach the starter motor to the transaxle and tighten bolts to specification.
Lower the vehicle. Install the rear engine mount bracket. See Figure . Using the 3 bar engine support and adapters, raise the engine and transaxle assembly.

NOTE: Install a NEW rear engine mount center retaining nut.

Install the rear engine mount, but DO NOT tighten the rear engine mount center retaining nut at this time. See Figure . Remove the 3 bar engine support and adapters. Raise and support the vehicle.
Install the accessory drive belt splash shield. Connect the VSS harness connector. See Figure . Install the front axle shafts. See FWD AXLE SHAFTS - FOCUS article in MANUAL TRANSMISSIONS.
Attach the gearshift cable retaining bracket to the transaxle. Install the gearshift cable and the selector cable to the selector levers. See Figure . Coat the exhaust flexible pipe studs with anti-seize grease.

NOTE: Install a NEW gasket and nuts.

Attach the exhaust flexible pipe to the tailpipe and muffler assembly. See Figure . Attach the catalytic converter to the exhaust manifold. Attach the HO2S sensor to the catalytic converter. See Figure . Install the catalytic converter bracket.

CAUTION: DO NOT excessively bend or twist the exhaust flexible pipe. Failure to follow this instructions may cause damage to the exhaust flexible pipe.

Attach the catalyst monitor sensor to the catalytic converter. Install the exhaust flexible pipe support. Connect the reverse light switch harness connector. See Figure .
Using a suitable transmission jack and the Subframe Alignment Pins (502-002, T94P-2100-AH), position and align the subframe. Insert the subframe alignment pins through the subframe alignment holes and washers. See Fig 1 .

NOTE: While tightening the subframe retaining bolts, make sure the subframe does not move.

Slide the locking plates on top of the washers and into the groove of the tool and tighten the alignment pin sleeve. Raise the subframe, engaging the alignment pins into the chassis aligning holes. Install the subframe retaining bolts. See Figure .
Lower and remove the transmission jack. Remove the subframe alignment pins. See Fig 1 . Check the power steering gear "O" ring seals for perishing, splits or cuts. See Fig 2 . Install NEW power steering gear "O" ring seals as necessary.
Attach the power steering lines to the power steering gear and tighten retaining bolt to specification. See Figure . See TORQUE SPECIFICATIONS . Rotate the power steering line clamp counterclockwise.
Attach the power steering line to the clamp. See Figure . Install the power steering gear heat shield (2 bolts). See Figure . Tighten power steering gear heat shield bolts to specification. See TORQUE SPECIFICATIONS .

CAUTION: Make sure the heat shields are installed to prevent damage to the ball joint.

Install the center retaining bolt to front roll restrictor and tighten to specification. See Figure . See TORQUE SPECIFICATIONS . Install the lower arm ball joint heat shield on both sides. Attach the lower arm ball joint to the wheel knuckle on both sides.
Using an Allen key to prevent the stabilizer bar link ball joint from rotating, attach the stabilizer bar connecting link to the stabilizer bar on both sides and tighten to specification. See TORQUE SPECIFICATIONS .
Using NEW retaining nuts, attach the tie-rod ends to the wheel knuckle on both sides and tighten to specification. See TORQUE SPECIFICATIONS . Install the front wheel/tire assemblies.

CAUTION: Ensure the front wheels are in straight ahead position.

Using a NEW retaining bolt, connect the steering column shaft to the steering gear pinion extension and tighten to specification. See Figure . See TORQUE SPECIFICATIONS . Fill and bleed the power steering system.
Using an Allen key to prevent the piston rod from rotating, tighten the right and left side strut mount nuts to specification. See TORQUE SPECIFICATIONS .
Connect the clutch slave cylinder supply line to the transaxle and install the clip. See Figure . Attach the engine-to-transaxle harness connector. Install the starter motor retaining bolts and the ground cable retaining bolt to the transaxle. See Figure .
Tighten the starter motor retaining bolts and the ground cable retaining bolt to specification. See TORQUE SPECIFICATIONS . Install the upper transaxle flange retaining bolts and tighten to specification.

NOTE: The resonator is plugged into the bracket.

Tighten the rear engine mount retaining nuts to specification. See Figure . See TORQUE SPECIFICATIONS . Install the intake tube, attach the ground lead and install the air cleaner and intake pipe. Install the battery tray. Install battery and connect both cables.

NOTE: The gearshift lever must rest in the shift passage between 3rd and 4th gear.

Adjust the gearshift cables. See SERVICING - M/T article in MANUAL TRANSMISSIONS. Bleed the clutch system. See BLEEDING HYDRAULIC SYSTEM . Fill transaxle to proper level with appropriate fluid. See SERVICING - M/T article in MANUAL TRANSMISSIONS.

Fig 1: Identifying Subframe Alignment Pins

Courtesy of FORD MOTOR CO.

Fig 2: Checking Power Steering Gear Line "O" Rings

Courtesy of FORD MOTOR CO.

Using a retaining strap and wooden blocks, secure the transaxle on a transmission jack. Push the engine forwards and install a long wooden block, approximately 14" (350 mm), between the engine and the crossmember. See Figure . Move the transaxle into position.
Install the right side and lower transaxle flange bolts. Tighten right side and lower transaxle flange bolts to specification. See TORQUE SPECIFICATIONS . Remove the retaining strap from the transaxle. Remove the wooden block. Remove the transmission jack. Connect the VSS harness connector. See Figure . Lower the vehicle.
Install the 2 upper transaxle flange bolts. Insert the 3 starter motor bolts (2 bolts shown), and tighten to specification. See Figure . See TORQUE SPECIFICATIONS . Install the rear engine mount bracket. See Figure .
Using the 3 bar engine support and adapters, raise the engine and transaxle assembly slightly. Install the rear engine mount and tighten bolts to specification. See Figure . See TORQUE SPECIFICATIONS . Remove the 3 bar engine support and adapters.
Connect the reverse light switch harness connector. See Figure . Connect the clutch slave cylinder supply line and insert the clip. Attach the gearshift and selector cables to the bracket and turn the abutment sleeves counterclockwise. See Figure .
Raise the vehicle and install the accessory drive belt splash shield. Install axle shafts. See FWD AXLE SHAFTS - FOCUS article in MANUAL TRANSMISSIONS. Install the lower arm ball joints on both sides and tighten lower arm ball joint pinch bolts to specification. See TORQUE SPECIFICATIONS .

NOTE: The resonator is a push fit into the bracket.

Install the front roll restrictor. See Figure . Install the flexible exhaust pipe and tighten bolts to specification. See TORQUE SPECIFICATIONS .
Install the front wheel/tire assemblies and lower the vehicle. Install the air cleaner intake, resonator and intake tube. Install the ground cable bolt (located near washer fluid reservoir). Install the air cleaner housing, intake hose, crankcase ventilation hose and MAF sensor harness connector.
Using an Allen key to prevent the piston rod from rotating, tighten the right and left side suspension strut lock nuts to specification. See TORQUE SPECIFICATIONS .
Install battery tray. Attach the wiring harness to the battery tray. See Figure . Tighten the battery tray bolts to specification. See TORQUE SPECIFICATIONS . Install harness connector at battery tray. Install the battery. Connect positive battery cable at battery.
Adjust the gearshift cables. See SERVICING - M/T article in MANUAL TRANSMISSIONS. Bleed the hydraulic clutch system. See BLEEDING HYDRAULIC SYSTEM .
Fill the transaxle to proper level with appropriate fluid. See SERVICING - M/T article in MANUAL TRANSMISSIONS. Connect the negative battery cable at battery. Carry out a road test to enable the Powertrain Control Module (PCM) to collect data.
Check the routing of the vacuum hoses and wiring and secure them with cable ties. Check fluid level after the road test and correct as necessary. Check the engine and cooling system for leaks (visual inspection).