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Home >> Ford >> 2012 >> Taurus Limited, AWD >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transaxle - 6F50/6F55 >> Removal And Installation >> Transaxle - 3.5L GTDI >> Installation

Transaxle - 3.5L GTDI: Installation

NOTE: Prior to installation of a new, re-manufactured or overhauled transaxle, the transmission fluid cooler tubes must be cleaned, otherwise transaxle failure may occur.
NOTE: Prior to installation of a new, re-manufactured or overhauled transaxle, flush out the cooler and cooler tubes. For additional information, refer to TRANSMISSION FLUID COOLER BACKFLUSHING AND CLEANING  .
  1. Inspect the transmission fluid cooler tube backing rings and seals for damage and install new backing rings or seals if necessary. Lubricate the transmission fluid cooler tube seals with clean transmission fluid and install the backing rings and seals on the transmission fluid cooler tubes.
    Fig 1: Identifying Seal And Backing Ring
    G06067701Courtesy of FORD MOTOR CO.
    Item Part Number Description
    1 7D285 Seal
    2 7J324 Backing ring
  2. Position the transmission fluid cooler thermal bypass valve and transmission fluid cooler tube assembly in place and install the thermal bypass valve nuts.
    • Tighten to 9 Nm (80 lb-in).
      Fig 2: Locating Thermal Bypass Valve Nuts
      G06068146Courtesy of FORD MOTOR CO.
  3. Install new transmission fluid cooler tube-to-transaxle case bolts.
    • Tighten to 9 Nm (80 lb-in).
      Fig 3: Locating Transmission Fluid Cooler Tube Bolts
      G06068147Courtesy of FORD MOTOR CO.
  4. Lubricate the torque converter pilot hub with grease.
    5. NOTE: If the transaxle is not positioned on the dowel pins, damage to the transaxle may occur.
    Fig 4: Locating Dowel Pins
    G06068149Courtesy of FORD MOTOR CO.
  5. If the dowel pins were pulled out of the engine block during removal, install new dowel pins in the engine block.
  6. Using the Transmission Jack Adapter, support the transaxle and position it in place on the engine dowel pins.
    Fig 5: Supporting Transaxle Using Transmission Jack Adapter
    G06068135Courtesy of FORD MOTOR CO.
  7. Install the lower torque converter housing bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 6: Locating Lower Torque Converter Housing Bolts
      G08000873Courtesy of FORD MOTOR CO.
  8. Install the transmission fluid cooler tubes in the transmission fluid cooler thermal bypass valve.
    Fig 7: Locating Transmission Fluid Cooler Tubes
    G06068154Courtesy of FORD MOTOR CO.
  9. Install the transmission fluid cooler tube secondary latches on the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.
    Fig 8: Locating Secondary Latches
    G06062156Courtesy of FORD MOTOR CO.
    10. NOTE: Use only the specified bolts for the torque converter. Standard length fasteners may bottom out and damage the torque converter clutch apply surface.
  10. Install 3 new torque converter bolts (W714722).
    • Install the first torque converter bolt in the slotted hole on the flexplate.
    • Tighten to 55 Nm (41 lb-ft).
      Fig 9: Locating Torque Converter Bolts
      G08000785Courtesy of FORD MOTOR CO.
  11. Install the inspection cover and the 2 fasteners.
    Fig 10: Locating Fasteners And Torque Converter Inspection Cover
    G06068129Courtesy of FORD MOTOR CO.
  12. Install the Power Transfer Unit (PTU). For additional information, refer to TRANSFER CASE - POWER TRANSFER UNIT (PTU) .
  13. Install the LH halfshaft. For additional information, refer to DRIVELINE SYSTEM - GENERAL INFORMATION .
  14. Install the front subframe. For additional information, refer to UNI-BODY, SUBFRAME AND MOUNTING SYSTEM .
    • Tighten the roll restrictor bracket bolts to 90 Nm (66 lb-ft).
      Fig 11: Locating Roll Restrictor Bracket Bolts
      G06260781Courtesy of FORD MOTOR CO.
  15. Position the transaxle support insulator in place and install the 2 upper bolts.
    • Tighten to 55 Nm (41 lb-ft).
      Fig 12: Locating Upper Transaxle Support Insulator Bolts
      G06260132Courtesy of FORD MOTOR CO.
  16. Install the 2 lower transaxle support insulator bolts.
    • Tighten to 55 Nm (41 lb-ft).
      Fig 13: Locating Lower Transaxle Support Insulator Bolts
      G06260131Courtesy of FORD MOTOR CO.
  17. Install the transaxle support insulator bracket and install the bolt and the 3 nuts.
    • Tighten the bolt to 80 Nm (59 lb-ft).
    • Tighten the nuts to 63 Nm (46 lb-ft).
      Fig 14: Locating Transaxle Support Insulator Bracket Bolts And Nuts
      G06260133Courtesy of FORD MOTOR CO.
  18. Remove the Engine Support Bar.
    Fig 15: Identifying Engine Support Bar
    G06260130Courtesy of FORD MOTOR CO.
  19. Install the strut tower brace and the 4 nuts.
    • Tighten to 30 Nm (22 lb-ft).
      Fig 16: Locating Strut Tower Brace Nuts
      G08001886Courtesy of FORD MOTOR CO.
  20. Remove the 2 front Engine Lift Eye bolts and remove the Engine Spreader Bar and the front Engine Lift Eye.
    Fig 17: Identifying Engine Spreader Bar And Engine Lift Eye
    G06260129Courtesy of FORD MOTOR CO.
  21. Install the cowl panel grille. For additional information, refer to FRONT END BODY PANELS .
  22. Align the index marks made during removal and install the Charge Air Cooler (CAC) hose on the RH turbocharger and tighten the clamp.
    • Tighten to 5 Nm (44 lb-in).
      Fig 18: Locating Charge Air Cooler Hose Clamp
      G06260127Courtesy of FORD MOTOR CO.
  23. Install the RH CAC hose nut.
    • Tighten to 10 Nm (89 lb-in).
      Fig 19: Locating RH CAC Hose Nut
      G06260126Courtesy of FORD MOTOR CO.
  24. Position the LH exhaust manifold heat shield in place and install the 4 bolts.
    • Tighten to 15 Nm (133 lb-in).
      Fig 20: Locating LH Exhaust Manifold Heat Shield And Bolts
      G06260790Courtesy of FORD MOTOR CO.
  25. Install the oil supply tube bracket on the LH valve cover stud bolt and install the nut.
    • Tighten to 8 Nm (71 lb-in).
      Fig 21: Locating LH Valve Cover Stud Bolt
      G06260124Courtesy of FORD MOTOR CO.
  26. Attach the wiring harness retainer to the valve cover stud bolt.
    Fig 22: Locating Valve Cover Stud Bolt Wiring Harness Retainer
    G06260123Courtesy of FORD MOTOR CO.
  27. Install the engine cover mounting stud to the LH valve cover stud bolt.
    • Tighten to 6 Nm (53 lb-in).
      Fig 23: Locating Engine Cover Mounting Stud
      G06260122Courtesy of FORD MOTOR CO.
  28. Install the crankcase vent tube and connect the 2 quick connect couplings.
    Fig 24: Locating Crankcase Vent Tube And Quick Connect Couplings
    G06260121Courtesy of FORD MOTOR CO.
  29. Install the top torque converter housing bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 25: Locating Top Torque Converter Housing Bolts
      G06068105Courtesy of FORD MOTOR CO.
  30. Attach the 2 wiring harness retainers to the transaxle stud bolts.
    Fig 26: Locating Transaxle Stud Bolt Wiring Harness Retainers
    G06260307Courtesy of FORD MOTOR CO.
  31. Attach the transaxle control wire harness retainer to the transaxle stud bolt.
    Fig 27: Locating Transaxle Control Wire Harness Retainer And Transaxle Stud Bolt
    G08000903Courtesy of FORD MOTOR CO.
  32. Connect the transaxle control electrical connector.
    Fig 28: Locating Transaxle Control Electrical Connector
    G07997916Courtesy of FORD MOTOR CO.
  33. Install the starter, the starter bolt and starter studbolt.
    • Tighten to 26 Nm (19 lb-ft).
      Fig 29: Locating Starter Bolt And Studbolt
      G07997914Courtesy of FORD MOTOR CO.
  34. Install the wiring harness fastener on the starter motor studbolt.
    Fig 30: Locating Starter Motor Stud Bolt
    G07997913Courtesy of FORD MOTOR CO.
  35. Connect the starter motor terminals.
    • Tighten the starter battery terminal nut to 12 Nm (106 lb-in).
    • Tighten the starter solenoid terminal nut to 6 Nm (53 lb-in).
      Fig 31: Locating Starter Motor Terminals
      G06062172Courtesy of FORD MOTOR CO.
  36. Install the starter motor terminal cover.
    Fig 32: Locating Starter Motor Positive Terminal Cover
    G07997911Courtesy of FORD MOTOR CO.
  37. Position the selector lever cable and bracket in place and install the selector lever cable bracket bolts.
    • Tighten to 12 Nm (106 lb-in).
      Fig 33: Locating Selector Lever Cable And Bracket Bolts
      G06068096Courtesy of FORD MOTOR CO.
  38. Attach the wiring harness pin-type retainer.
    Fig 34: Locating Wiring Harness Pin-Type Retainer
    G06260299Courtesy of FORD MOTOR CO.
  39. Place the selector lever in DRIVE.
    Fig 35: Locating Selector Lever In Drive Position
    G06260761Courtesy of FORD MOTOR CO.
  40. Place the manual control lever in DRIVE.
    1. Rotate the manual control lever clockwise until it stops.
    2. Rotate the manual control lever counterclockwise one detent until it stops.
      Fig 36: Rotating Manual Control Lever Clockwise
      G06067707Courtesy of FORD MOTOR CO.
  41. Unlock the selector lever cable adjuster by sliding the locking tab over.
    Fig 37: Sliding Adjuster Locking Tab
    G06067708Courtesy of FORD MOTOR CO.
  42. Slide the cable end forward or backward to align it with the manual lever.
    Fig 38: Aligning Selector Lever Cable With Manual Control Lever
    G06067709Courtesy of FORD MOTOR CO.
  43. With the adjuster locking tab released, connect the selector lever cable end to the manual control lever.
    Fig 39: Locating Manual Control Lever End
    G06067710Courtesy of FORD MOTOR CO.
  44. Slide the release tab back to lock the adjuster.
    Fig 40: Sliding Adjuster Tab To LOCK Position
    G06067711Courtesy of FORD MOTOR CO.
  45. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  46. Fill the transaxle with clean transmission fluid. For additional information, refer to TRANSMISSION FLUID DRAIN AND REFILL  .
  47. If a new solenoid body is installed, the solenoid body strategy will need to be updated. For additional information, refer to SOLENOID BODY STRATEGY  .
  48. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.
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