Automatic Transmission - 6 Speed: Installation: Transaxle

SPECIAL TOOLS REFERENCE

Courtesy of FORD MOTOR CO.	Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool
Courtesy of FORD MOTOR CO.	Universal Adapter Bracket 014-0001
Courtesy of FORD MOTOR CO.	Engine Lifting Bracket Set 307-1140
Courtesy of FORD MOTOR CO.	Support Bar, Engine 303-290A
Courtesy of FORD MOTOR CO.	Adapters for 303-290A 303-290A-01
Courtesy of FORD MOTOR CO.	Adapter for 303-290A (Support Leg) 303-290A-03A
Courtesy of FORD MOTOR CO.	Lifting Bracket, Engine 303-050 (T70P-6000)
Courtesy of FORD MOTOR CO.	Adapter for 303-290A (Lifting Hook) 303-290A-12

MATERIAL SPECIFICATIONS

Item	Specification
Motorcraft Premium Automatic Transmission Fluid XT-8-QAW	WSS-M2C924-A
Multi-Purpose Grease XG-4 and/or XL-5	ESB-M1C93-B
Threadlock and Sealer TA-25	WSK-M2G351-A5

CAUTION: MERCON®, MERCON®V, MERCON®SP, Motorcraft Premium Automatic Transmission Fluid and Motorcraft Continuously Variable Chain Type Transmission Fluid are not interchangeable transmission fluids. The use of any fluid other than what is recommended for this transmission will cause transmission damage.

NOTE: If the transaxle was overhauled, or if installing a new transaxle and the transmission fluid cooler has not been flushed, flush the fluid cooler at this time. For additional information, refer to TRANSMISSION FLUID COOLER - BACKFLUSHING AND CLEANING .

Prior to installing the transaxle, apply multi-purpose grease to the torque converter pilot hub.

Fig 1: Identifying Torque Converter Pilot Hub
Courtesy of FORD MOTOR CO.
Position the transaxle to the back of the engine.
Install the 5 transaxle-to-engine bolts.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 2: Locating Transaxle-To-Engine Bolts
  Courtesy of FORD MOTOR CO.
Install 3 new torque converter nuts.
- Tighten to 36 Nm (27 lb-ft).
  
  Fig 3: Locating Torque Converter Nuts
  Courtesy of FORD MOTOR CO.
Install the inspection cover.

Fig 4: Identifying Inspection Cover
Courtesy of FORD MOTOR CO.
Connect the transmission fluid cooler hoses to the transaxle.

Fig 5: Locating Transmission Fluid Cooler Hoses
Courtesy of FORD MOTOR CO.
Position the ground cable and the heated oxygen sensor (HO2S) bracket in place and install the bolts.
- Tighten to 12 Nm (9 lb-ft).
  
  Fig 6: Locating Heated Oxygen Sensor Bracket Bolts
  Courtesy of FORD MOTOR CO.
Position the RH halfshaft in the transaxle and install the 2 bolts.
- Tighten to 55 Nm (41 lb-ft).
  
  Fig 7: Locating Transaxle Bolts
  Courtesy of FORD MOTOR CO.
Install the bolt retaining the brake caliper hose.
- Tighten to 22 Nm (16 lb-ft).
  
  Fig 8: Identifying Brake Caliper Hose Bolt
  Courtesy of FORD MOTOR CO.
Connect the HO2S to the RH halfshaft bearing support bracket.

Fig 9: Identifying RH Halfshaft Bearing Support Bracket
Courtesy of FORD MOTOR CO.
Position the subframe in place using a suitable powertrain lift.

NOTE: LH shown, RH similar.

Install the front subframe nuts.
- Tighten to 150 Nm (111 lb-ft).
  
  Fig 10: Locating Front Subframe Nuts
  Courtesy of FORD MOTOR CO.
Position the subframe support brackets in place and loosely install the bolts.

Fig 11: Locating Subframe Support Brackets Bolts
Courtesy of FORD MOTOR CO.
Install the rear subframe nuts.
- Tighten to 150 Nm (111 lb-ft).
  
  Fig 12: Locating Rear Subframe Nuts
  Courtesy of FORD MOTOR CO.
Tighten the subframe support bracket bolts.
- Tighten to 103 Nm (76 lb-ft).
  
  Fig 13: Locating Subframe Support Bracket Bolts
  Courtesy of FORD MOTOR CO.
Install the bolt connecting the RH damper fork to the lower control arm.
- Tighten to 103 Nm (76 lb-ft).
  
  Fig 14: Locating Lower Control Arm Bolt
  Courtesy of FORD MOTOR CO.
Position the lower control arms in the knuckle and install the nuts.
- Tighten to 200 Nm (148 lb-ft).
  
  Fig 15: Identifying Lower Control Arms Nuts
  Courtesy of FORD MOTOR CO.
LH shown, RH similar.
Position the sway bar links in the struts and install the nuts.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 16: Locating Sway Bar Links Strut Nuts
  Courtesy of FORD MOTOR CO.
Position the steering gear in place and install the 3 bolts.
- Tighten to 107 Nm (79 lb-ft).
  
  Fig 17: Locating Steering Gear Bolts
  Courtesy of FORD MOTOR CO.
Position the power steering cooler tube in place and install the bolts.
- Tighten to 9 Nm (80 lb-in).
  
  Fig 18: Locating Power Steering Cooler Tube Bolts
  Courtesy of FORD MOTOR CO.
Install the LH front structure to subframe splash shield and install the pin-type retainers.

Fig 19: Locating Subframe Splash Shield
Courtesy of FORD MOTOR CO.
Position the LH fender splash shield in place and install the 4 screws.

Fig 20: Locating LH Fender Splash Shield Screws
Courtesy of FORD MOTOR CO.
Position the RH front structure-to-subframe splash shield in place and install the 6 pin-type retainers.

Fig 21: Identifying RH Front Structure-To-Subframe Splash Shield
Courtesy of FORD MOTOR CO.
Position the RH fender splash shield in place and install the 4 screws.

Fig 22: Locating RH Fender Splash Shield Screws
Courtesy of FORD MOTOR CO.
Position the transaxle insulator bracket in place and install the 2 nuts and the bolt.
- Tighten to 80 Nm (59 lb-ft).
  
  Fig 23: Locating Transaxle Insulator Bracket Nuts And Bolt
  Courtesy of FORD MOTOR CO.
Raise the transaxle and install the 2 bolts.
- Tighten to 62 Nm (46 lb-ft).
  
  Fig 24: Locating Transaxle Bolts
  Courtesy of FORD MOTOR CO.
Remove the special tools.

Fig 25: Identifying Special Tools
Courtesy of FORD MOTOR CO.
Remove the universal lifting brackets from the LH side of the engine.

Fig 26: Identifying Universal Lifting Brackets
Courtesy of FORD MOTOR CO.
Remove the upper half of the lifting hook.

Fig 27: Locating Lifting Hook
Courtesy of FORD MOTOR CO.
Remove the lower half of the lifting hook.

Fig 28: Identifying Lower Half Of Lifting Hook
Courtesy of FORD MOTOR CO.
Install the LH halfshaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
Install the roll restrictor and the 3 bolts.
- Tighten to 90 Nm (66 lb-ft).
  
  Fig 29: Locating Roll Restrictor Bolts
  Courtesy of FORD MOTOR CO.
Install the roll restrictor heat shield and the bolts.

Fig 30: Locating Roll Restrictor Heat Shield And Bolts
Courtesy of FORD MOTOR CO.
Install the catalytic converter-to-engine block bracket and install the 2 bolts.
- Tighten to 35 Nm (26 lb-ft).
  
  Fig 31: Locating Catalytic Converter-To-Engine Block Bracket And Bolts
  Courtesy of FORD MOTOR CO.
Install the catalytic converter band clamp and the 2 bolts.
- Tighten to 20 Nm (15 lb-ft).
  
  Fig 32: Locating Catalytic Converter Band Clamp And Bolts
  Courtesy of FORD MOTOR CO.
Install the RH exhaust manifold heat shield and the 2 bolts.
- Tighten to 11 Nm (8 lb-ft).
  
  Fig 33: Locating RH Exhaust Manifold Heat Shield And Bolts
  Courtesy of FORD MOTOR CO.
Position the Y-pipe assembly in place and install the 2 flexpipe nuts.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 34: Locating Flexpipe Nuts
  Courtesy of FORD MOTOR CO.
Install the 2 Y-pipe bolts and the 2 Y-pipe nuts.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 35: Locating Y-Pipe Bolts And Y-Pipe Nuts
  Courtesy of FORD MOTOR CO.
Loosely install the exhaust gas recirculation (EGR) tube nut on the RH exhaust manifold.

Fig 36: Locating Exhaust Gas Recirculation Tube Nut
Courtesy of FORD MOTOR CO.
If equipped, install the splash shield and the 7 bolts.

Fig 37: Locating Splash Shield Bolts
Courtesy of FORD MOTOR CO.
Position the power steering line bracket on the right cylinder head and install the bolt.
- Tighten to 7 Nm (62 lb-in).
  
  Fig 38: Locating Power Steering Line Bracket Bolt
  Courtesy of FORD MOTOR CO.
Install a new gasket and the EGR valve and install the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 39: Locating EGR Valve And Bolts
  Courtesy of FORD MOTOR CO.
Install the EGR tube on the valve.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 40: Identifying EGR Tube On Valve
  Courtesy of FORD MOTOR CO.
Connect the EGR valve electrical connector.

Fig 41: Locating EGR Valve Electrical Connector
Courtesy of FORD MOTOR CO.
Tighten the EGR tube at the RH exhaust manifold.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 42: Identifying EGR Tube At RH Exhaust Manifold
  Courtesy of FORD MOTOR CO.
Install the 3 upper transaxle-to-engine retaining bolts.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 43: Locating Upper Transaxle-To-Engine Retaining Bolts
  Courtesy of FORD MOTOR CO.
Install the starter and the 2 bolts.
- Tighten to 26 Nm (19 lb-ft).
  
  Fig 44: Locating Starter Bolts
  Courtesy of FORD MOTOR CO.
Connect the 2 starter motor electrical connectors.
- Tighten the larger nut to 12 Nm (9 lb-ft).
- Tighten the smaller nut to 5 Nm (44 lb-in).
  
  Fig 45: Identifying Starter Motor Electrical Connectors
  Courtesy of FORD MOTOR CO.
Install the electrical cover for the starter motor electrical connectors.

Fig 46: Identifying Electrical Cover For Starter Motor Electrical Connectors
Courtesy of FORD MOTOR CO.
Connect the wire harness fastener to the transaxle.

Fig 47: Identifying Wire Harness Fastener
Courtesy of FORD MOTOR CO.
Connect the transmission control module (TCM) electrical connector.

Fig 48: Identifying Transmission Control Module Electrical Connector
Courtesy of FORD MOTOR CO.
Position the shift cable and bracket in place and install the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 49: Locating Shift Cable And Bracket Bolts
  Courtesy of FORD MOTOR CO.
Connect the shift cable end.

Fig 50: Locating Shift Cable End
Courtesy of FORD MOTOR CO.
Remove the transmission fluid fill plug.

Fig 51: Locating Transmission Fluid Fill Plug
Courtesy of FORD MOTOR CO.
Fill the transaxle with clean automatic transmission fluid.
Install the fluid fill plug.
- Tighten to 39 Nm (29 lb-ft).
  
  Fig 52: Locating Transmission Fluid Fill Plug
  Courtesy of FORD MOTOR CO.
Install the air cleaner and outlet tube. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING - 2.3L or INTAKE AIR DISTRIBUTION & FILTERING - 3.0L (4V) .
Install the battery tray and the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
Remove the fluid level indicator and make sure that the transaxle has fluid in it.
With the transaxle in (P) PARK, the vehicle on a level surface, the engine at idle (680-780 RPM) and foot pressed on the brake, move the selector lever through each gear and allow engagement of each gear. Place the selector lever back in the PARK position.
Wipe the fluid level indicator cap and remove the fluid level indicator.
Wipe the fluid level indicator with a clean cloth.

NOTE: In order to get an accurate fluid level reading the vehicle should be on a level surface. Idle the engine to reach the normal operating temperature. Using the WDS, verify that the transaxle is at normal operating temperature 60°C - 70°C (140°F - 158°F), prior to adjusting the transmission fluid level.

Fig 53: Locating Fluid Level Indicator

Courtesy of FORD MOTOR CO.

If fluid needs to be added, add fluid in 0.25 L (1/2 pint) increments through the fluid fill plug located on the top of the transaxle near the fluid level indicator. Do not overfill the fluid. Install the fluid level indicator back in the fluid filler tube until it is fully seated, then remove the indicator. The fluid level should be at the upper most mark on the fluid level indicator. Only fill to the upper most mark on the fluid indicator. Do not overfill. Damage to the transaxle will occur.

NOTE: The correct transmission fluid level at normal operating temperature of 60°C - 70°C (140°F - 158°F) is between the top 2 marks on the fluid level indicator.

Fig 54: Locating Marks On Fluid Level Indicator

Courtesy of FORD MOTOR CO.

Fill the transaxle to the correct fluid level.

NOTE: The correct transmission fluid level at cold operating temperature of 15°C - 25°C (59°F - 77°F) is at the bottom mark on the fluid level indicator.

Fig 55: Locating Bottom Mark On Fluid Level Indicator

Courtesy of FORD MOTOR CO.

If the transmission fluid temperature is low, fill the fluid to the cold range on the fluid level indicator. Recheck the fluid level when the transaxle has reached the normal operating temperature.