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Manual Transmission: Installation: Transaxle: Material

MATERIAL

Item Specification
Premium Long-Life Grease XG-1-C or XG-1-K (Canada CXG-1-C) ESA-M1C75-B
  1. Do not lubricate the splines on the input shaft.
    2. WARNING: Secure the transaxle to the transmission jack with a safety chain. Failure to follow these instructions may result in personal injury.
  2. Raise and position the transaxle.
  3. Install the 3 short transaxle-to-engine bolts.
    • Tighten to 47 Nm (35 lb-ft).
  4. Install the long transaxle-to-engine bolt.
    • Tighten to 47 Nm (35 lb-ft).
  5. Install the exhaust outlet pipe. For additional information, refer to EXHAUST SYSTEM .
  6. Install the transaxle front support insulator bracket.
    1. Install the transaxle front support insulator bracket.
    2. Install the 3 bolts.
      • Tighten to 55 Nm (41 lb-ft).
    3. Install the transaxle front support insulator.
    4. Install the through-bolt.
      • Tighten to 90 Nm (66 lb-ft).
        Fig 1: Installing Through-Bolt
        G03901871Courtesy of FORD MOTOR CO.
    7. CAUTION: Make sure to use the seal protector when installing the RH intermediate shaft and the LH halfshaft. Failure to use the seal protector may result in transmission oil leaks.
  7. Install the RH intermediate axleshaft and the LH halfshaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
  8. If equipped, install the transfer case. For additional information, refer to TRANSFER CASE-POWER TRANSFER UNIT (PTU) .
  9. Install the starter motor assembly. For additional information, refer to STARTING SYSTEM .
  10. Install the LH side splash shield.
    1. Position the LH splash shield.
    2. Install the 2 screws.
      Fig 2: Positioning LH Splash Shield
      G03901872Courtesy of FORD MOTOR CO.
  11. Install the 3 LH splash shield screws.
    Fig 3: Installing LH Splash Shield Screws
    G03901756Courtesy of FORD MOTOR CO.
  12. Install the front-to-aft crossmember.
    1. Position the crossmember.
    2. Install the 2 front-to-aft crossmember bolts and nut.
      • Tighten to 90 Nm (66 lb-ft).
    3. Install the splash shield screw.
    4. Install the 2 transaxle front support insulator bolts.
      • Tighten to 90 Nm (66 lb-ft).
        Fig 4: Installing Transaxle Front Support Insulator Bolts
        G03901874Courtesy of FORD MOTOR CO.
  13. Install the crossmember.
    1. Position the crossmember.
    2. Install the bolts.
      • Tighten to 115 Nm (85 lb-ft).
        Fig 5: Installing Bolts
        G03901875Courtesy of FORD MOTOR CO.
  14. Install the 3 upper transaxle-to-engine bolts. Tighten the bolts to 45 Nm (33 lb-ft).
    Fig 6: Installing Upper Transaxle-To-Engine Bolts
    G03901753Courtesy of FORD MOTOR CO.
  15. Install the transaxle rear support insulator.
    1. Position the transaxle rear support insulator.
    2. Install the through-bolt.
      • Tighten to 90 Nm (66 lb-ft).
    3. Install the nuts.
      • Tighten to 90 Nm (66 lb-ft).
    4. Install the bolt.
      • Tighten to 90 Nm (66 lb-ft).
        Fig 7: Installing Bolt
        G03901877Courtesy of FORD MOTOR CO.
  16. Install the LH transaxle support insulator bracket.
    1. Position the LH transaxle support insulator bracket.
    2. Install the through-bolt.
      • Tighten to 90 Nm (66 lb-ft).
    3. Install the 3 nuts.
      • Tighten to 90 Nm (66 lb-ft).
        Fig 8: Installing Nuts
        G03901878Courtesy of FORD MOTOR CO.
  17. Install the shift cable bracket.
    1. Position the shift cable bracket.
    2. Install the 3 bolts.
      • Tighten to 22 Nm (16 lb-ft).
        Fig 9: Installing Bolts
        G03901879Courtesy of FORD MOTOR CO.
  18. Connect the clutch hydraulic line.
    1. Position the clutch hydraulic line.
    2. Connect the clutch hydraulic line from the clutch slave cylinder.
    3. Install the clutch hydraulic line bracket-to-transaxle bolt.
      • Tighten to 2.5 Nm (22 lb-in).
        Fig 10: Installing Clutch Hydraulic Line Bracket-To-Transaxle Bolt
        G03901880Courtesy of FORD MOTOR CO.
  19. Connect the shift cables.
    Fig 11: Connecting Shift Cables
    G03901747Courtesy of FORD MOTOR CO.
  20. Connect the reverse switch and vehicle speed sensor (VSS) connectors.
    Fig 12: Connecting Reverse Switch And Vehicle Speed Sensor (VSS) Connectors
    G03901746Courtesy of FORD MOTOR CO.
  21. Install the wiring harness bracket nuts.
    • Tighten to 12 Nm (9 lb-ft).
      Fig 13: Installing Wiring Harness Bracket Nuts
      G03901745Courtesy of FORD MOTOR CO.
  22. Install the air cleaner outlet tube.
    1. Install the air cleaner outlet tube.
    2. Tighten the clamp.
    3. Connect the emission management tube and hose.
      Fig 14: Connecting Emission Management Tube And Hose
      G03901884Courtesy of FORD MOTOR CO.
  23. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  24. Install the air cleaner assembly. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - 2.3L .
  25. Fill the transaxle fluid. For additional information, refer to TRANSAXLE DRAINING AND FILLING .
  26. Fill and bleed the clutch. For additional information, refer to MANUAL TRANSAXLE-TRANSMISSION AND CLUTCH - GENERAL INFORMATION .
  27. Adjust the shift cables.
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