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Section 303 (Automatic Transmission): Installation: Transaxle: Installation

WARNING: This page is about a different car, the 2003 Ford Focus. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: The location of the engine mountings and the engine support insulators are given looking from the automatic transaxle to the engine.
NOTE: Only install new self-locking nuts.
  1. Make sure that the torque converter is installed correctly.
    2. NOTE: Lubricate the torque converter pilot hub with multi-purpose grease.
    Fig 1: Checking Installation Depth Of Torque Converter
    G01612986Courtesy of FORD MOTOR CO.
  2. Check the installation depth of the torque converter.
    1. Lay a steel straightedge on the automatic transaxle flange.
    2. Check the installation depth between the transaxle flange and the torque converter centering spigot for the correct clearance.
  3. Remove the special tool.
    Fig 2: Removing Special Tool
    G01612987Courtesy of FORD MOTOR CO.
  4. Raise and support the vehicle. For additional information, refer to JACKING & HOISTING .
  5. Using a retaining strap secure the transaxle on a transmission jack.
    6. NOTE: Make sure that the dowel pins are installed in the engine block prior to installing the transaxle.
  6. Move the transaxle into position.
    7. NOTE: The location of the different length bolts.
    Fig 3: Installing Left-Hand Flange Bolts
    G01612988Courtesy of FORD MOTOR CO.
  7. Install the left-hand flange bolts.
  8. Install the torque converter to the engine drive plate (four nuts).
    Fig 4: Installing Torque Converter To Engine Drive Plate
    G01612989Courtesy of FORD MOTOR CO.
  9. Remove the retaining strap and wooden block from the transaxle.
  10. Install the torque converter cover (if equipped).
    Fig 5: Installing Torque Converter Cover
    G01612990Courtesy of FORD MOTOR CO.
  11. Install the right-hand flange bolt.
    Fig 6: Installing Right-Hand Flange Bolt
    G01612991Courtesy of FORD MOTOR CO.
  12. Install the fluid filler pipe.
    Fig 7: Installing Fluid Filler Pipe
    G01612992Courtesy of FORD MOTOR CO.
  13. Install the starter motor.
    • Insert the three bolts (two bolts shown).
    Fig 8: Installing Starter Motor
    G01612993Courtesy of FORD MOTOR CO.
  14. Connect the starter motor electrical connectors.
    Fig 9: Connecting Starter Motor Electrical Connectors
    G01612994Courtesy of FORD MOTOR CO.
  15. Lower the vehicle.
    16. NOTE: The location of the different length bolts.
    Fig 10: Installing Upper Flange Bolts
    G01612995Courtesy of FORD MOTOR CO.
  16. Install the two upper flange bolts.
  17. Install the engine rear mounting bracket.
    Fig 11: Installing Engine Rear Mounting Bracket
    G01612996Courtesy of FORD MOTOR CO.
  18. Using the special tool, raise the engine and transaxle assembly slightly.
  19. Install the engine rear mounting.
    Fig 12: Installing Engine Rear Mounting
    G01612997Courtesy of FORD MOTOR CO.
  20. Remove the special tools.
    Fig 13: Removing Special Tool From Engine
    G01612998Courtesy of FORD MOTOR CO.
  21. Raise and support the vehicle. For additional information, refer to JACKING & HOISTING .
    22. CAUTION: The inner joint must not be bent at more than 18 degrees; the outer joint must not be bent at more than 45 degrees.
    NOTE: Install new nuts and a new center bearing cap.
    Fig 14: Installing Right-Hand Front Drive Halfshaft Together With Intermediate Shaft
    G01612999Courtesy of FORD MOTOR CO.
  22. Install the right-hand front drive halfshaft together with the intermediate shaft.
    23. CAUTION: The inner joint must not be bent at more than 18 degrees; the outer joint must not be bent at more than 45 degrees.
    NOTE: Install a new snap ring.
    Fig 15: Installing Left-Hand Front Drive Halfshaft
    G01613000Courtesy of FORD MOTOR CO.
  23. Install a left-hand front drive halfshaft (shown with subframe removed).
  24. Install the lower suspension arm.
    1. Attach the suspension arm bolt joint.
    2. Install the bolt.
    Fig 16: Installing Lower Suspension Arm
    G01613001Courtesy of FORD MOTOR CO.
  25. Install the left-hand tie-rod end.
    Fig 17: Installing Left-Hand Tie-Rod End
    G01613002Courtesy of FORD MOTOR CO.
  26. Install the engine right-hand support insulator.
    Fig 18: Installing Engine Right-Hand Support Insulator
    G01613003Courtesy of FORD MOTOR CO.
  27. Connect the output speed (OSS) sensor electrical connector.
    Fig 19: Connecting Output Speed (OSS) Sensor Electrical Connector
    G01613004Courtesy of FORD MOTOR CO.
    28. CAUTION: Do not loosen the connecting fitting from the transaxle housing.
    NOTE: Location marks.
    Fig 20: Installing Fluid Cooler Pipes
    G01613005Courtesy of FORD MOTOR CO.
  28. Install the fluid cooler pipes.
  29. Install the exhaust pipe and the exhaust pipe bracket.
    • Install a new gasket and new nuts.
    • Coat the studs with anti seize grease.
    Fig 21: Installing Exhaust Pipe And Exhaust Pipe Bracket
    G01613006Courtesy of FORD MOTOR CO.
  30. Install the left-hand front wheel and tire. For additional information, refer to WHEELS & TIRES .
  31. Install the fluid filler pipe/selector lever cable bracket.
    Fig 22: Installing Fluid Filler Pipe/Selector Lever Cable Bracket
    G01613007Courtesy of FORD MOTOR CO.
  32. Connect the electrical connectors and install the selector lever cable to the automatic transaxle selector lever.
    1. Transmission range (TR) sensor.
    2. Automatic transaxle.
    Fig 23: Connecting Electrical Connectors And Installing Selector Lever Cable To Automatic Transaxle Selector Lever
    G01613008Courtesy of FORD MOTOR CO.
  33. Connect the vacuum hoses.
    1. Evaporative emission (EVAP) system.
    2. Brake servo.
    3. Delta pressure feedback electronic (DPFE) system.
    4. Exhaust gas recirculation (EGR) valve.
    Fig 24: Connecting Vacuum Hoses
    G01613009Courtesy of FORD MOTOR CO.
  34. Connect the turbine shaft speed (TSS) sensor electrical connector.
    Fig 25: Connecting Turbine Shaft Speed (TSS) Sensor Electrical Connector
    G01613010Courtesy of FORD MOTOR CO.
    35. NOTE: The resonator is plugged into the bracket.
    Fig 26: Installing Air Cleaner Intake Pipe With Resonator
    G01613011Courtesy of FORD MOTOR CO.
  35. Install the air cleaner intake pipe with the resonator.
  36. Install the intake tube.
    Fig 27: Installing Intake Tube
    G01613012Courtesy of FORD MOTOR CO.
  37. Install the air cleaner housing.
    • Press the air cleaner housing into the rubber bushes.
    1. Install the mass air flow (MAF) sensor electrical connector.
    2. Install the crankcase ventilation hose.
    3. Connect the air cleaner outlet hose.
    Fig 28: Installing Air Cleaner Housing
    G01613013Courtesy of FORD MOTOR CO.
  38. Tighten the left-hand strut and spring assembly top mount nuts.
    Fig 29: Tightening Left-Hand Strut And Spring Assembly Top Mount Nuts
    G01613014Courtesy of FORD MOTOR CO.
  39. Install the battery tray.
    1. Attach the wiring harness.
    2. Install in the bolts.
    3. Connect and secure the electrical connector.
    Fig 30: Installing Battery Tray
    G01613015Courtesy of FORD MOTOR CO.
  40. Install the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  41. Check the fluid levels and correct as necessary.
  42. Check the routing of the vacuum hoses and wiring and secure them with cable ties.
  43. Enter the radio keycode.
  44. Reprogram the preset radio stations.
  45. Reset the clock.
  46. Fill the engine coolant system. For additional information, refer to ENGINE COOLING .
  47. Fill the transaxle with automatic transmission fluid.
    48. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.
  48. Finishing operations:
    • Check fluid level after the road test and correct as necessary.
    • Check the engine and cooling system for leaks (visual inspection).
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