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Engine - Automatic Transaxle

Special Tools

Illustration Tool Name Tool Number
GF0000536Courtesy of FORD MOTOR CO.
 Heavy Duty Floor Crane 014-00071 or equivalent
GF0000160Courtesy of FORD MOTOR CO.
 Lifting Bracket, Engine 303-050 (T70P-6000)
GF0019593Courtesy of FORD MOTOR CO.
 Powertrain Lift 014-00765 or equivalent
GF0000267Courtesy of FORD MOTOR CO.
 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
GF0024108Courtesy of FORD MOTOR CO.
 Universal Adapter Brackets 014-0001 or equivalent
Material

Item Specification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil
XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalent		 WSS-M2C930-A
Multi-Purpose Grease
XG-4 and/or XL-5		 ESB-M1C93-B
    NOTE: Lubricate the torque converter pilot hub with multi-purpose grease.
  1. Check the installation depth of the torque converter.
    1. Lay a 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.
    2. Fig 1: Locating Depth Between Transaxle Flange And Torque Converter Centering Spigot For Correct Clearance
    GF0039373Courtesy of FORD MOTOR CO.
  2. Using the Heavy Duty Floor Crane and Spreader Bar, position the engine and transaxle together. Install the 6 bellhousing-to-engine fasteners.
    • Tighten to 48 Nm (35 lb-ft).
  3. Using the Heavy Duty Floor Crane, Engine Lifting Bracket and Spreader Bar, raise the engine and transaxle assembly onto the lift table.
    4. Fig 2: Identifying Heavy Duty Floor Crane, Engine Lifting Bracket And Spreader Bar
    GF0043144Courtesy of FORD MOTOR CO.
  4. Using the Powertrain Lift and Universal Adapter Brackets, secure the engine and transaxle assembly to the lift table.
    5. Fig 3: Identifying Powertrain Lift And Universal Adapter Brackets
    GF0043128Courtesy of FORD MOTOR CO.
  5. Install the 7 new catalytic converter manifold studs.
    • Tighten to 17 Nm (150 lb-in).
    6. Fig 4: Identifying Studs
    GF0043143Courtesy of FORD MOTOR CO.
    NOTE: If new parts are not being used, be sure to align the marks on the flexplate and the stud made during engine removal.
  6. Install the 4 torque converter nuts.
    • Tighten to 35 Nm (26 lb-ft).
    7. Fig 5: Locating Torque Converter Nut
    G03897896Courtesy of FORD MOTOR CO.
  7. Install the starter motor isolator.
    8. Fig 6: Identifying Starter Motor Isolator
    G03897895Courtesy of FORD MOTOR CO.
  8. Install the starter motor, stud bolt and the bolt.
    • Install the upper bolt and lower stud bolt finger-tight.
    • Tighten the upper bolt to 35 Nm (26 lb-ft).
    • Tighten the lower stud bolt to 35 Nm (26 lb-ft).
    9. Fig 7: Identifying Bolt, Stud Bolt And Starter
    GF0043142Courtesy of FORD MOTOR CO.
  9. Position the 2 power steering tubes and the wiring harness as an assembly on the engine.
    10. Fig 8: Identifying Power Steering Tubes
    GF0043141Courtesy of FORD MOTOR CO.
  10. Install the engine ground wire and the bolt.
    • Tighten to 48 Nm (35 lb-ft).
    11. Fig 9: Identifying Bolt And Gorund Wire
    GF0043140Courtesy of FORD MOTOR CO.
  11. Install the power steering tube bracket on the starter motor stud bolt and install the nut.
    • Tighten to 20 Nm (177 lb-in).
    12. Fig 10: Identifying Bolt And Bracket
    GF0043139Courtesy of FORD MOTOR CO.
  12. Attach the starter wire harness retainer to the starter motor stud bolt.
    13. Fig 11: Identifying Stud Bolt
    GF0043138Courtesy of FORD MOTOR CO.
  13. Connect the starter motor electrical terminals and install the 2 nuts.
    • Tighten the small nut to 5 Nm (44 lb-in).
    • Tighten the large nut to 12 Nm (106 lb-in).
    14. Fig 12: Locating Starter Motor Electrical Terminals
    GF0039321Courtesy of FORD MOTOR CO.
  14. Connect the Crankshaft Position (CKP) sensor electrical connector.
    15. Fig 13: Identifying Connector
    GF0043137Courtesy of FORD MOTOR CO.
  15. Attach the 2 CKP sensor wire harness retainers.
    16. Fig 14: Identifying Retainers
    GF0043136Courtesy of FORD MOTOR CO.
  16. Connect the Power Steering Pressure (PSP) switch electrical connector.
    17. Fig 15: Identifying (PSP) Connector
    GF0043135Courtesy of FORD MOTOR CO.
  17. Connect the A/C compressor electrical connector.
    18. Fig 16: Identifying A/C Compressor Electrical Connector
    GF0043134Courtesy of FORD MOTOR CO.
  18. Connect the Turbine Shaft Speed (TSS) sensor electrical connector.
    19. Fig 17: Locating Turbine Shaft Speed (TSS) Sensor Electrical Connector
    GF0039344Courtesy of FORD MOTOR CO.
  19. Connect the Output Shaft Speed (OSS) sensor electrical connector.
    20. Fig 18: Locating Output Shaft Speed Sensor Electrical Connector
    GF0039343Courtesy of FORD MOTOR CO.
  20. Position the Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS) wire connector bracket and install the nut.
    • Tighten to 25 Nm (18 lb-ft).
    21. Fig 19: Identifying Nut And Bracket
    GF0043133Courtesy of FORD MOTOR CO.
  21. Install the nut for the HO2S and CMS wire connector bracket.
    • Tighten to 25 Nm (18 lb-ft).
    22. Fig 20: Identifying Nut
    GF0043132Courtesy of FORD MOTOR CO.
  22. Using the lift table, position the engine and transaxle assembly in the vehicle.
  23. Install the transaxle mount plate and the 5 nuts.
    • Tighten the center nut to 150 Nm (111 lb-ft).
    • Tighten the 4 outer nuts to 48 Nm (35 lb-ft).
    24. Fig 21: Identifying Nuts
    GF0043131Courtesy of FORD MOTOR CO.
  24. Install the engine mount and the 2 bolts and the stud bolt.
    • Tighten to 48 Nm (35 lb-ft).
    25. Fig 22: Identifying Bolts, Stud Bolt And Engine Mount
    GF0043130Courtesy of FORD MOTOR CO.
  25. Install the 2 motor mount nuts.
    • Tighten to 90 Nm (66 lb-ft).
    26. Fig 23: Identifying Engine Mount Nuts
    GF0043129Courtesy of FORD MOTOR CO.
  26. Install the 2 oil pan-to-bellhousing bolts.
    • Tighten to 48 Nm (35 lb-ft).
    27. Fig 24: Locating Engine-To-Bellhousing Bolts
    GF0024138Courtesy of FORD MOTOR CO.
  27. Install the 2 lower bellhousing-to-oil pan bolts.
    • Tighten to 48 Nm (35 lb-ft).
    28. Fig 25: Locating Lower Bellhousing Bolts
    GF0024137Courtesy of FORD MOTOR CO.
    NOTE: The bolts are different lengths, make sure the bolts are in the correct location.
  28. Install the transaxle roll restrictor and the 2 bolts.
    1. Install the transaxle roll restrictor.
    2. Install the short bolt.
    3. Install the long bolt.
      • Tighten to 70 Nm (52 lb-ft).
    29. Fig 26: Identifying Transaxle Roll Restrictor, Short Bolt And Long Bolt
    GF0043170Courtesy of FORD MOTOR CO.
  29. Position the transaxle fluid indicator tube and install the bolt.
    • Tighten to 8 Nm (71 lb-in).
    30. Fig 27: Identifying Bolt
    GF0043125Courtesy of FORD MOTOR CO.
  30. Install the transaxle fluid indicator tube bracket bolt.
    • Tighten to 8 Nm (71 lb-in).
    31. Fig 28: Identifying Bolt
    GF0043126Courtesy of FORD MOTOR CO.
  31. Attach the wire harness retainer to the transaxle fluid indicator tube.
    32. Fig 29: Identifying Retainer
    GF0043124Courtesy of FORD MOTOR CO.
  32. Install the transaxle fluid indicator.
    33. Fig 30: Identifying Transaxle Fluid Level Indicator
    GF0043123Courtesy of FORD MOTOR CO.
  33. Connect the throttle control electrical connector.
    34. Fig 31: Identifying Throttle Control Electrical Connector
    GF0043122Courtesy of FORD MOTOR CO.
  34. Connect the heater hose to the coolant tube.
    35. Fig 32: Identifying coolant Tube
    GF0043121Courtesy of FORD MOTOR CO.
  35. Connect the upper radiator hose, the heater hose to the coolant bypass.
    36. Fig 33: Identifying Heater Hose And Coolant Bypass
    GF0043120Courtesy of FORD MOTOR CO.
  36. Install the power steering pump. For additional information, refer to POWER STEERING article.
  37. Clean and inspect the catalytic converter flange.
    • Using a straightedge and feeler gauge, place the straightedge across the catalytic converter flange surface and check for warping with the feeler gauge. If the reading is greater than the maximum specification, install a new catalytic converter, gasket and nuts.
      • Fig 34: Inspecting Catalytic Converter Flange W/Specs.
      GF0039278Courtesy of FORD MOTOR CO.
    38. CAUTION: Failure to tighten the catalytic converter nuts to specification before installing the converter bracket bolts will cause the converter to develop an exhaust leak.
    CAUTION: Failure to tighten the catalytic converter nuts to specification a second time will cause the converter to develop an exhaust leak.
  38. Using a new gasket and 7 new nuts, install the catalytic converter and tighten in 2 stages in the sequence shown.
    • Stage 1: Tighten to 55 Nm (41 lb-ft).
    • Stage 2: Tighten to 55 Nm (41 lb-ft).
    39. Fig 35: Exhaust Manifold Nut Torque Sequence
    GF0025494Courtesy of FORD MOTOR CO.
  39. Install the heat shield and 6 bolts.
    • Tighten to 11 Nm (97 lb-in).
    40. Fig 36: Identifying Bolts
    GF0043118Courtesy of FORD MOTOR CO.
  40. Install the catalytic converter support bracket and the 2 bolts.
    • Tighten to 22 Nm (16 lb-ft).
    41. Fig 37: Identifying Bolts And Catalytic Converter Support Bracket
    GF0043117Courtesy of FORD MOTOR CO.
  41. Install the 2 catalytic converter support bracket-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
    42. Fig 38: Locating Catalytic Converter Support Bracket And Bolts
    GF0039271Courtesy of FORD MOTOR CO.
    NOTE: Clean the mating surfaces of the muffler and tail pipe assembly and flexpipe.
  42. Using a new gasket and 2 new nuts, connect the flexpipe to the muffler and tail pipe assembly.
    • Tighten to 48 Nm (35 lb-ft).
    43. Fig 39: Identifying Nuts
    GF0043116Courtesy of FORD MOTOR CO.
  43. Using 2 new O-ring seals, install the power steering tubes to the steering gear and install the bolt.
    • Tighten to 18 Nm (159 lb-in).
    44. Fig 40: Identifying Bolt And Power Steering Tubes
    GF0043115Courtesy of FORD MOTOR CO.
  44. Install the power steering tube clip and the bolt.
    45. Fig 41: Identifying Bolt And Clip
    GF0043114Courtesy of FORD MOTOR CO.
  45. Install the LH halfshaft. For additional information, refer to FRONT DRIVE HALFSHAFTS article.
    46. NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter.
  46. Install a new engine oil filter.
    • Tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter adapter.
    47. Fig 42: Identifying Engine Oil Filter
    GF0043082Courtesy of FORD MOTOR CO.
  47. Connect the lower radiator hose to the radiator.
    48. Fig 43: Identifying Lower Radiator Hose
    GF0043113Courtesy of FORD MOTOR CO.
  48. Install the cooling fan motor and shroud. For additional information, refer to ENGINE COOLING article.
  49. Using 2 new O-ring seals, connect the A/C tubes to the compressor.
    50. Fig 44: Identifying O-Ring Seals
    GF0043112Courtesy of FORD MOTOR CO.
  50. Install the A/C tube bracket to the A/C compressor stud bolt and install the nut.
    • Tighten to 10 Nm (89 lb-in).
    51. Fig 45: Identifying Nut And Bolt
    GF0043111Courtesy of FORD MOTOR CO.
  51. Install the 2 A/C tube nuts.
    • Tighten to 15 Nm (133 lb-in).
    52. Fig 46: Identifying A/C Tube Nuts
    GF0043110Courtesy of FORD MOTOR CO.
  52. Position and attach the 4 B+ battery cable wire harness retainers (2 shown).
    53. Fig 47: Identifying B+ Battery Cable Wire Harness Retainers
    GF0043109Courtesy of FORD MOTOR CO.
  53. Install the generator. For additional information, refer to CHARGING SYSTEM - GENERAL INFORMATION article.
  54. Install the accessory drive belt and tensioner. For additional information, refer to ACCESSORY DRIVE article.
  55. Install the splash shield and the retainers.
    56. Fig 48: Locating Retainers And Engine Undershield
    GF0039383Courtesy of FORD MOTOR CO.
  56. Install the 2 front wheels and tires. For additional information, refer to WHEELS AND TIRES article.
  57. Install the radio capacitor ground cable and the bolt.
    • Tighten to 10 Nm (89 lb-in).
    58. Fig 49: Identifying Bolt
    GF0043108Courtesy of FORD MOTOR CO.
  58. Install the engine oil level indicator.
    59. Fig 50: Identifying Engine Oil Level Indicator
    GF0043107Courtesy of FORD MOTOR CO.
  59. Attach the shift cable to the retainer.
    60. Fig 51: Identifying Retainer
    GF0043106Courtesy of FORD MOTOR CO.
  60. Connect the 2 transaxle electrical connectors.
    61. Fig 52: Identifying Connectors
    GF0043105Courtesy of FORD MOTOR CO.
  61. Install the transmission fluid cooler tubes on the transaxle and slide the latches to the locked position.
    62. Fig 53: Identifying Latches
    GF0043171Courtesy of FORD MOTOR CO.
  62. Install the secondary latches.
    63. Fig 54: Identifying Transmission Fluid Cooler Tube Secondary Latches
    GF0043103Courtesy of FORD MOTOR CO.
  63. Connect the transaxle shift cable to the lever and bracket.
    64. Fig 55: Identifying Lever And Bracket
    GF0043102Courtesy of FORD MOTOR CO.
  64. Connect the HO2S and CMS electrical connectors and attach the wire harness retainer.
    65. Fig 56: Identifying (HO2S) And (CMS) Connectors And Retainer
    GF0043101Courtesy of FORD MOTOR CO.
  65. Connect the starter wire harness electrical connector.
    66. Fig 57: Identifying Starter Wire Harness Electrical Connector
    GF0043100Courtesy of FORD MOTOR CO.
  66. Connect the 3 PCM electrical connectors.
    67. Fig 58: Identifying PCM Electrical Connectors
    GF0043099Courtesy of FORD MOTOR CO.
  67. Attach the engine harness to the coolant outlet bracket harness retainer.
    68. Fig 59: Identifying Coolant Outlet Bracket Harness Retainer
    GF0043098Courtesy of FORD MOTOR CO.
  68. Connect and attach the 2 engine harness electrical connectors.
    69. Fig 60: Identifying Engine Harness Electrical Connectors
    GF0043097Courtesy of FORD MOTOR CO.
  69. Attach the brake booster vacuum hose retainer.
    70. Fig 61: Identifying Brake Booster Vacuum Hose Retainer
    GF0043096Courtesy of FORD MOTOR CO.
  70. Install the power brake booster vacuum tube into the quick connect fitting.
    71. Fig 62: Locating Power Brake Booster Vacuum Tube And Quick Release Locking Ring
    GF0024064Courtesy of FORD MOTOR CO.
  71. Position and connect the Evaporative Emission (EVAP) tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
    72. Fig 63: Identifying Evaporative Emission (EVAP)
    GF0043095Courtesy of FORD MOTOR CO.
  72. Connect the fuel tube quick connect coupling to the fuel rail. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
    73. Fig 64: Identifying Fuel Tube Quick Connect Coupling
    GF0043094Courtesy of FORD MOTOR CO.
  73. Install the negative battery cable ground and the bolt.
    • Tighten to 6 Nm (53 lb-in).
    74. Fig 65: Identifying Bolt
    GF0043093Courtesy of FORD MOTOR CO.
  74. Attach the 2 positive battery cable wire harness retainer.
    75. Fig 66: Identifying Positive Battery Cable Wire Harness Retainers
    GF0043092Courtesy of FORD MOTOR CO.
  75. Connect the positive battery cable nut.
    • Tighten to 10 Nm (89 lb-in).
    76. Fig 67: Identifying Positive Battery Cable Nut
    GF0043091Courtesy of FORD MOTOR CO.
  76. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
  77. Connect the crankcase vent tube to the valve cover.
    78. Fig 68: Identifying Crankcase Vent Tube And Valve Cover
    GF0043090Courtesy of FORD MOTOR CO.
  78. Install the Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING article.
  79. Fill the engine with clean engine oil.
  80. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING article.
  81. Evacuate and charge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS article.
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