Transaxle - 2.0L: Installation

All Vehicles 

1. Make sure that the torque converter is installed correctly.
NOTE: Lubricate the torque converter pilot hub with multi-purpose grease.
Fig 1: Checking Installation Depth Of Torque Converter
Courtesy 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

   Courtesy of FORD MOTOR CO.
4. Using a retaining strap secure the transaxle on a transmission jack.
NOTE: Make sure that the dowel pins are installed in the engine block prior to installing the transaxle.
5. Move the transaxle into position.
NOTE: The location of the different length bolts.
Fig 3: Installing Left-Hand Flange Bolts
Courtesy of FORD MOTOR CO.
6. Install the left-hand flange bolts.
7. Install the torque converter to the engine drive plate (four nuts).
   • Rotate the crankshaft to install all the nuts.
   Fig 4: Installing Torque Converter To Engine Drive Plate Nuts

   Courtesy of FORD MOTOR CO.

   Vehicles With 2.0L SPI Engine 

8. Install the torque converter cover (if equipped).
   Fig 5: Installing Torque Converter Cover

   Courtesy of FORD MOTOR CO.

   Vehicles With 2.0L Zetec Engine 

9. Install the access plug.
   Fig 6: Installing Access Plug

   Courtesy of FORD MOTOR CO.

   All Vehicles 

10. Install the necessary drive belt cover.
    Fig 7: Installing Necessary Drive Belt Cover

    Courtesy of FORD MOTOR CO.
11. Remove the retaining strap and the transmission jack from the transaxle.
12. Install the right-hand flange bolt.
    Fig 8: Installing Right-Hand Flange Bolt

    Courtesy of FORD MOTOR CO.
13. Install the fluid filler pipe.
    Fig 9: Installing Fluid Filler Pipe

    Courtesy of FORD MOTOR CO.
14. Install the starter motor lower retainer bolt.
    • Loosely install one upper bolt.
    Fig 10: Installing Starter Motor Lower Retainer Bolt

    Courtesy of FORD MOTOR CO.
15. Connect the starter motor electrical connectors.
    Fig 11: Connecting Starter Motor Electrical Connectors

    Courtesy of FORD MOTOR CO.
16. Lower the vehicle.
NOTE: The location of the different length bolts.
Fig 12: Installing Upper Flange Bolts
Courtesy of FORD MOTOR CO.
17. Install the two upper flange bolts.
18. Install the engine rear mounting bracket.
    Fig 13: Installing Engine Rear Mounting Bracket

    Courtesy of FORD MOTOR CO.
19. Using the special tools, raise the engine and transaxle assembly slightly.
20. Install the engine rear mounting.
    Fig 14: Installing Engine Rear Mounting

    Courtesy of FORD MOTOR CO.
21. Remove the special tools.
    Fig 15: Removing Special Tools

    Courtesy of FORD MOTOR CO.

    Vehicles With 2.0L SPI Engine 

22. Remove both of the engine lifting brackets.
    Fig 16: Removing Engine Lifting Brackets

    Courtesy of FORD MOTOR CO.

    All Vehicles 

23. Raise and support the vehicle.
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 17: Installing Right-Hand Front Drive Halfshaft Together With Intermediate Shaft
Courtesy of FORD MOTOR CO.
24. Install the right-hand front drive halfshaft together with the intermediate shaft.
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 18: Installing Left-Hand Front Drive Half Shaft
Courtesy of FORD MOTOR CO.
25. Install a left-hand front drive half shaft (shown with subframe removed).
26. Install the lower suspension arm.
    1. Attach the suspension arm bolt joint.
    2. Install the bolt.
    Fig 19: Installing Lower Suspension Arm

    Courtesy of FORD MOTOR CO.
27. Install the left-hand tie-rod end.
    Fig 20: Installing Left-Hand Tie-Rod End

    Courtesy of FORD MOTOR CO.
28. Install the engine right-hand support insulator.
    Fig 21: Installing Engine Right-Hand Support Insulator

    Courtesy of FORD MOTOR CO.
29. Connect the output speed (OSS) sensor electrical connector.
    Fig 22: Connecting OSS Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
CAUTION: Do not loosen the connecting fitting from the transaxle housing.
NOTE: Location marks.
Fig 23: Installing Fluid Cooler Pipes
Courtesy of FORD MOTOR CO.
30. Install the fluid cooler pipes.
31. Install the front wheels and tires. For additional information, refer to WHEELS AND TIRES .

    Vehicles With 2.0L Zetec Engine 

32. Install the transaxle lower flange bolts.
    Fig 24: Installing Transaxle Lower Flange Bolts

    Courtesy of FORD MOTOR CO.
33. Lower the vehicle.

    Vehicles With 2.0L SPI Engine 

34. Install the transaxle lower flange bolts.
    Fig 25: Installing Transaxle Lower Flange Bolts

    Courtesy of FORD MOTOR CO.
35. Install the catalytic converter. For additional information, refer to EXHAUST SYSTEM .

    All Vehicles 

36. Install the fluid filler pipe/selector lever cable bracket.
    Fig 26: Installing Fluid Filler Pipe/Selector Lever Cable Bracket

    Courtesy of FORD MOTOR CO.
37. Install the upper starter motor bolts.
    Fig 27: Installing Upper Starter Motor Bolts

    Courtesy of FORD MOTOR CO.
38. 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 28: Connecting Electrical Connectors & Selector Lever Cable To Automatic Transaxle Selector Lever

    Courtesy of FORD MOTOR CO.
39. Connect the turbine shaft speed (TSS) sensor electrical connector.
    Fig 29: Connecting TSS Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
NOTE: The resonator is plugged into the bracket.
Fig 30: Installing Air Cleaner Intake Pipe With Resonator
Courtesy of FORD MOTOR CO.
40. Install the air cleaner intake pipe with the resonator.
41. Install the intake tube.
    Fig 31: Installing Intake Tube

    Courtesy of FORD MOTOR CO.
42. Install the air cleaner housing.
    • Press the air cleaner housing into the rubber bushes.
    • Install the mass air flow (MAF) sensor electrical connector.
    • Install the crankcase ventilation hose.
    • Connect the air cleaner outlet hose.
    Fig 32: Installing Air Cleaner Housing

    Courtesy of FORD MOTOR CO.
43. Tighten the left-hand strut and spring assembly top mount nuts.
    Fig 33: Tightening Left-Hand Strut And Spring Assembly Top Mount Nuts

    Courtesy of FORD MOTOR CO.
44. Install the battery tray.
    1. Attach the wiring harness.
    2. Install in the bolts.
    3. Connect and secure the electrical connector.
    Fig 34: Installing Battery Tray

    Courtesy of FORD MOTOR CO.
45. Install the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
46. Check the routing of the vacuum hoses and wiring and secure them with cable ties.
47. Fill the transaxle with automatic transmission fluid.
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).