Transaxle - 3.5L: Installation

All vehicles 

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.

   Item	Part Number	Description
   1	7D285	Seal
   2	7J324	Backing ring

   Fig 1: Identifying Seal And Backing Ring

   Courtesy of FORD MOTOR CO.
2. Position the transmission fluid cooler thermal bypass valve and transmission fluid cooler tube assembly in place and install the nuts.
   • Tighten to 9 Nm (80 lb-in).
     Fig 2: Locating Thermal Bypass Valve Nuts

     Courtesy 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

     Courtesy of FORD MOTOR CO.
NOTE: Make sure that when installing the manual control lever, it is fully seated onto the manual control lever shaft. Damage to the manual control lever shaft will occur and the lever will come loose.
NOTE: Make sure to hold the manual control lever while tightening the manual control lever nut or damage to the manual control lever and park components will occur.
4. Install the manual control lever and the nut.
   • Tighten to 18 Nm (159 lb-in).
     Fig 4: Locating Manual Control Lever And Mounting Nut

     Courtesy of FORD MOTOR CO.
5. Lubricate the torque converter pilot hub with grease.
NOTE: If the transaxle is not positioned on the dowel pins, damage to the transaxle may occur.
Fig 5: Locating Dowel Pins
Courtesy of FORD MOTOR CO.
6. If the dowel pins were pulled out of the engine block during removal, install new dowel pins in the engine block.
7. Using the Transmission Jack Adapter, support the transaxle.
   Fig 6: Supporting Transaxle Using Transmission Jack Adapter

   Courtesy of FORD MOTOR CO.
8. Position the transaxle in place and install the lower torque converter housing bolts.
   • Tighten to 48 Nm (35 lb-ft).
     Fig 7: Locating Lower Torque Converter Housing Bolts

     Courtesy of FORD MOTOR CO.
9. Install the transaxle support insulator bracket, the nuts and the bolt.
   • Tighten the bolt to 80 Nm (59 lb-ft).
   • Tighten the nuts to 63 Nm (46 lb-ft).
     Fig 8: Locating Nuts, Bolt And Transaxle Support Insulator Bracket

     Courtesy of FORD MOTOR CO.
10. Raise the transaxle and install the transaxle support insulator through bolt.
    • Tighten to 175 Nm (129 lb-ft).
      Fig 9: Locating Transaxle Support Bolt

      Courtesy of FORD MOTOR CO.
11. Install the transmission fluid cooler tubes in the transmission fluid cooler thermal bypass valve.
    Fig 10: Locating Transmission Fluid Cooler Tubes

    Courtesy of FORD MOTOR CO.
12. Install the secondary latches on the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.
    Fig 11: Locating Secondary Latches

    Courtesy of FORD MOTOR CO.
NOTE: Use only the specified bolts for the torque converter. Standard length fasteners may bottom out and damage the torque converter clutch apply surface.
13. 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 12: Locating Torque Converter Bolts

      Courtesy of FORD MOTOR CO.
14. Install the inspection cover and the 2 fasteners.
    Fig 13: Locating Fasteners And Torque Converter Inspection Cover

    Courtesy of FORD MOTOR CO.

    All-Wheel Drive (AWD) vehicles 

15. Position the Power Transfer Unit (PTU) in place and install the bolts.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 14: Locating Power Transfer Unit (PTU) Bolts

      Courtesy of FORD MOTOR CO.
16. Position the PTU support bracket in place and install the bolts.
    • Tighten to 70 Nm (52 lb-ft).
      Fig 15: Locating Power Transfer Unit Support Bracket Bolts

      Courtesy of FORD MOTOR CO.
17. Position the RH catalytic converter in place and loosely install the 4 nuts.
    Fig 16: Locating RH Catalytic Converter Nuts

    Courtesy of FORD MOTOR CO.
18. Install the RH catalytic converter support bracket bolts.
    • Tighten to 20 Nm (177 lb-in).
      Fig 17: Locating Catalytic Converter Support Bracket Bolts

      Courtesy of FORD MOTOR CO.
19. Tighten the 4 RH catalytic converter nuts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 18: Locating RH Catalytic Converter Nuts

      Courtesy of FORD MOTOR CO.
20. Connect the RH catalyst monitor electrical connector.
    Fig 19: Locating RH Catalyst Monitor Electrical Connector

    Courtesy of FORD MOTOR CO.
21. Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal and install new bolts.
    • Tighten to 70 Nm (52 lb-ft).
      Fig 20: Locating Driveshaft Bolts

      Courtesy of FORD MOTOR CO.

    All vehicles 

22. Using the Powertrain Lift With Tilting Plate, raise the subframe into the installed position.
    Fig 21: Supporting Subframe Using Powertrain Lift

    Courtesy of FORD MOTOR CO.
NOTE: Support the subframe using the Powertrain Lift With Tilting Plate.
NOTE: RH shown in illustration, LH similar.
Fig 22: Locating Front Subframe Bolt
Courtesy of FORD MOTOR CO.
23. Loosely install the RH and LH front subframe bolts.
NOTE: RH shown in illustration, LH similar.
Fig 23: Locating Subframe Bracket And Bolts
Courtesy of FORD MOTOR CO.
24. Position the RH and LH subframe support brackets in place and loosely install the bracket bolts.
NOTE: RH shown in illustration, LH similar.
Fig 24: Locating Rear Subframe Bolt
Courtesy of FORD MOTOR CO.
25. Loosely install the RH and LH rear subframe bolts.
NOTE: RH shown in illustration, LH similar.
26. Tighten the RH and LH front subframe bolts.
    • Tighten to 150 Nm (111 lb-ft).
      Fig 25: Locating Front Subframe Bolt

      Courtesy of FORD MOTOR CO.
NOTE: RH shown in illustration, LH similar.
27. Tighten the RH and LH rear subframe bolts.
    • Tighten to 150 Nm (111 lb-ft).
      Fig 26: Locating Rear Subframe Bolt

      Courtesy of FORD MOTOR CO.
NOTE: RH shown in illustration, LH similar.
28. Tighten the RH and LH subframe support bracket bolts.
    • Tighten to 55 Nm (41 lb-ft).
      Fig 27: Locating Subframe Bracket-To-Body Bolts

      Courtesy of FORD MOTOR CO.
29. Install the roll restictor bracket and the 3 roll restrictor bracket bolts.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 28: Identifying Front And Rear Roll Restrictor Bracket Bolts

      Courtesy of FORD MOTOR CO.
30. Install the roll restrictor and the 2 roll restrictor through bolts.
    • Tighten to 103 Nm (76 lb-ft).
      Fig 29: Locating Roll Restrictor Mounting Bolts

      Courtesy of FORD MOTOR CO.
31. Position the stabilizer bar in place and install new bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 30: Locating Stabilizer Bar Bolts

      Courtesy of FORD MOTOR CO.
32. Position the power steering rack in place and install new bolts and nuts.
    • Tighten to 117 Nm (86 lb-ft).
      Fig 31: Locating Steering Rack Bolts

      Courtesy of FORD MOTOR CO.
33. Position the exhaust Y-pipe assembly in place and install the new nuts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 32: Locating Exhaust Y-Pipe Assembly And Nuts

      Courtesy of FORD MOTOR CO.
34. Install the exhaust hanger and the new Y-pipe gasket and new nuts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 33: Locating Y-Pipe Nuts And Exhaust Hanger

      Courtesy of FORD MOTOR CO.
35. Install the RH and LH halfshafts. For additional information, refer to FRONT DRIVE HALFSHAFTS .
36. Position the power steering tube in place on the LH side of the subframe and install the 3 power steering tube bracket bolts.
    • Tighten to 9 Nm (80 lb-in).
      Fig 34: Locating Power Steering Tube Bracket Bolt

      Courtesy of FORD MOTOR CO.
37. Install the front splash shield, the screws and the pushpin fasteners.
    Fig 35: Locating Front Splash Shield Screws And Pushpin Fasteners

    Courtesy of FORD MOTOR CO.
38. Install the RH splash shield and the pushpin fasteners.
    Fig 36: Locating RH Splash Shield And Pushpin Fasteners

    Courtesy of FORD MOTOR CO.
39. Remove the Engine Support Bar and Engine Spreader Bar.
    Fig 37: Installing Engine Support Bar And Engine Spreader Bar On Engine

    Courtesy of FORD MOTOR CO.
40. Remove the Engine Lift Eye from the LH cylinder head.
    Fig 38: Installing Engine Lift Eye On LH Cylinder Head

    Courtesy of FORD MOTOR CO.
41. Install the top torque converter housing bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 39: Locating Top Torque Converter Housing Bolts

      Courtesy of FORD MOTOR CO.
42. Connect the transaxle electrical connector and install the wiring harness fastener on the main control cover stud.
    Fig 40: Locating Transaxle Electrical Connector And Wiring Harness Fastener

    Courtesy of FORD MOTOR CO.
43. If equipped, position the auxiliary coolant pump on the transaxle studs and install the 2 nuts.
    • Tighten to 20 Nm (177 lb-in).
      Fig 41: Locating Auxiliary Coolant Pump Nuts

      Courtesy of FORD MOTOR CO.
44. Install the starter, the bolt and studbolt.
    • Tighten to 26 Nm (19 lb-ft).
      Fig 42: Locating Starter Bolt And Stud Bolt

      Courtesy of FORD MOTOR CO.
45. Install the wiring harness fastener on the starter motor studbolt.
    Fig 43: Locating Starter Motor Stud Bolt

    Courtesy of FORD MOTOR CO.
46. 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 44: Locating Starter Motor Terminals

      Courtesy of FORD MOTOR CO.
47. Install the starter motor positive terminal cover.
    Fig 45: Locating Starter Motor Positive Terminal Cover

    Courtesy of FORD MOTOR CO.
48. Position the selector lever cable and bracket in place and install the bolts.
    • Tighten to 12 Nm (106 lb-in).
      Fig 46: Locating Selector Lever Cable And Bracket Bolts

      Courtesy of FORD MOTOR CO.
49. Place the selector lever in DRIVE.
50. 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 47: Rotating Manual Control Lever Clockwise

       Courtesy of FORD MOTOR CO.
51. Unlock the selector lever cable adjuster by sliding the locking tab over.
    Fig 48: Sliding Adjuster Locking Tab

    Courtesy of FORD MOTOR CO.
52. Slide the cable end forward or backward to align it with the manual control lever.
    Fig 49: Aligning Selector Lever Cable With Manual Control Lever

    Courtesy of FORD MOTOR CO.
53. With the adjuster locking tab released, connect the selector lever cable end to the manual control lever.
    Fig 50: Locating Manual Control Lever End

    Courtesy of FORD MOTOR CO.
54. Slide the release tab back to lock the adjuster.
    Fig 51: Sliding Adjuster Tab To LOCK Position

    Courtesy of FORD MOTOR CO.
55. Install the upper intake manifold. For additional information, refer to ENGINE - 3.5L .
56. Install the battery tray and bracket, install the battery tray bolt and the nut.
    • Tighten to 9 Nm (80 lb-in).
      Fig 52: Locating Battery Tray Assembly Nut And Bolt

      Courtesy of FORD MOTOR CO.
57. Install the lower battery tray bracket bolts.
    • Tighten to 9 Nm (80 lb-in).
      Fig 53: Locating Lower Battery Tray Bracket Bolts

      Courtesy of FORD MOTOR CO.
58. Attach the pin-type wiring harness fasteners to the battery tray.
    Fig 54: Locating Battery Tray Wiring Harness Retainers

    Courtesy of FORD MOTOR CO.
59. Install the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
60. Position the Air Cleaner (ACL) assembly in place and install the ACL assembly bracket bolts.
    • Tighten to 11 Nm (97 lb-in).
      Fig 55: Locating ACL Assembly Bracket Bolts

      Courtesy of FORD MOTOR CO.
61. Connect the brake booster vacuum hose to the ACL outlet pipe.
    Fig 56: Locating Brake Booster Vacuum Hose

    Courtesy of FORD MOTOR CO.
62. Tighten the ACL outlet pipe clamp at the TB.
    • Tighten to 5 Nm (44 lb-in).
      Fig 57: Locating ACL Outlet Pipe Clamp

      Courtesy of FORD MOTOR CO.
63. Connect the engine breather to the ACL assembly.
    Fig 58: Locating ACL Assembly

    Courtesy of FORD MOTOR CO.
64. Connect the Mass Air Flow (MAF) sensor electrical connector and electrical harness fastener.
    Fig 59: Locating Mass Air Flow (MAF) Sensor And Electrical Connector

    Courtesy of FORD MOTOR CO.
65. Install the front wheels. For additional information, refer to WHEELS AND TIRES .
66. Fill with clean transmission fluid to the correct level.
67. If a new solenoid body is installed, the solenoid body strategy will need to be updated. Refer to SOLENOID BODY STRATEGY  .