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Removal & Installation: Transaxle: Installation

  1. Apply a thin coating of Premium Long-Life Grease (XG-1-C or K) or equivalent to the spline of the input shaft. Secure the transaxle on transmission jack. Raise the transaxle to the proper height and position the transaxle to the engine. Install the middle transaxle to engine bolts and tighten to specification. See TORQUE SPECIFICATIONS  .
  2. Install the lower transaxle to engine bolts. Install the clutch slave cylinder nuts. See Figure . Install the lower clutch slave cylinder tube and connect the tube nut. Position the transaxle gearshift rod and clevis to the input shift shaft and install the transaxle gearshift bolt and transaxle gearshift rod nut. See Figure .
  3. Install the gearshift stabilizer bar and support nut. See Figure . Install the catalytic converter bracket bolts and tighten catalytic converter bracket bolts to specification. See TORQUE SPECIFICATIONS  .
    4. NOTE: Inspect the catalytic converter for cracked joints, broken welds and corrosive damage that could result in exhaust system leaks. If necessary, replace the catalytic converter. Use a NEW exhaust converter inlet gasket between the catalytic converter and exhaust manifold. Use a NEW catalytic converter outlet gasket between the catalytic converter and the muffler inlet pipe.
  4. Install the NEW catalytic converter and catalytic converter-to-muffler inlet pipe gasket. Install the catalytic converter-to-muffler inlet pipe nuts and tighten converter-to-muffler inlet pipe nuts to specification. See TORQUE SPECIFICATIONS  .
  5. Install the transverse crossmember and tighten transverse crossmember bolts to specification. Install the NEW catalytic converter-to-exhaust manifold gasket and catalytic converter-to-exhaust manifold nuts.
  6. Tighten catalytic converter-to-exhaust manifold nuts to specification. See TORQUE SPECIFICATIONS  . Connect the downstream Catalyst Monitor Sensor (CMS) harness connector.
  7. Install the front engine crossmember bolts and nuts. See Figure . Install the lower front and lower rear insulator nuts. On vehicles with A/C, connect the A/C line to crossmember.
  8. On all vehicles, install the axle shafts. See FWD AXLE SHAFTS - ESCORT article in DRIVE AXLES. Install the front and rear upper transaxle to engine bolts.
  9. Install the starter motor. On vehicles equipped with SPI engines, go to next step. On vehicles equipped with Zetec engines, go to step  11 .
  10. Install the starter motor and solenoid assembly and install the lower starter motor bolt. Connect the "S" terminal wire, "B" terminal nut and cable to the starter motor. Lower the vehicle. Install the top starter motor bolts and tighten starter motor bolts to specification. See TORQUE SPECIFICATIONS  . Go to step  12 .
  11. Install the integral connector to starter and tighten nuts to specification. See TORQUE SPECIFICATIONS  . Install the starter motor into vehicle. Lower the vehicle, install the 3 starter retaining bolts and tighten to specification.
  12. Install the left side engine support insulator nuts and washers. See Figure . Remove three-bar engine support. Connect the PNP switch harness connector. See Figure . Install the reverse light switch harness connector bracket. Connect the reverse light switch harness connector. See Figure .
  13. Connect the HO2S harness connector. See Figure . Position the hydraulic clutch hose in the bracket and install the retaining clip. Connect the clutch slave cylinder tube nut to the hydraulic clutch hose.
  14. Bleed the hydraulic system. See BLEEDING HYDRAULIC SYSTEM  . Fill transaxle to appropriate level with proper fluid. See SERVICING - M/T article in MANUAL TRANSMISSIONS. Connect the VSS harness connector. See Figure .
  15. Install the battery tray and tighten battery tray bolts to specification. See Figure . See TORQUE SPECIFICATIONS  . Install the engine air cleaner. Install the Evaporative (EVAP) emission canister retainer at the battery tray (Mexico and leaded fuel vehicles only).
  16. Install the battery. Install the battery hold down bolt and the battery hold down clamp. See Figure . Install the battery cover. Connect the negative and positive battery cables. Check the system for normal operation.
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