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Automatic Transaxle/Transmission: Installation: Transaxle: Installation

All vehicles 

    NOTE: The self-locking nuts must be reserved.
  1. The location of engine mountings and roll resistors are described locking from the automatic transaxle to the engine.
    2. CAUTION: The torque converter is heavy. Install the special tool before raising the transaxle.
    CAUTION: The torque converter must remain at the correct installation depth throughout the whole installation procedure.
    NOTE: The torque converter studs must be aligned with the flexplate holes before any transaxle to engine bolts are installed.
    Fig 1: Installing Special Tool
    G02198819Courtesy of FORD MOTOR CO.
  2. Install the special tool.
    3. NOTE: The torque converter hub must engage fully in the oil pump drive gear.
    NOTE: Apply a thin layer of high-temperature grease to the centering spigot bore on the torque converter.
  3. Check the installation depth of the torque converter.
    1. Lay a steel 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.
      Fig 2: Checking Installation Depth Of Torque Converter
      G02198820Courtesy of FORD MOTOR CO.
    4. NOTE: Remove the special tool.
    Fig 3: Using Transmission Jack And CD4E Transaxle Adapter Raise And Position Transaxle
    G02198821Courtesy of FORD MOTOR CO.
  4. Using the transmission jack and the CD4E transaxle adapter raise and position the transaxle.
  5. Install the transaxle-to-engine bolts.
    Fig 4: Installing Transaxle-To-Engine Bolts
    G02198822Courtesy of FORD MOTOR CO.
  6. Install the transaxle-to-engine lower bolts.
    Fig 5: Installing Transaxle-To-Engine Lower Bolts
    G02198823Courtesy of FORD MOTOR CO.
  7. Install the torque converter nuts.
    • Install torque converter inspection cover.
      Fig 6: Installing Torque Converter Nuts
      G02198824Courtesy of FORD MOTOR CO.
  8. Connect the main control cover tube.
    Fig 7: Connecting Main Control Cover Tube
    G02198825Courtesy of FORD MOTOR CO.
    9. CAUTION: To avoid damage to joints and boots, do not bent the inner halfshaft joint by more than 18 degrees, the outer one by more than 45 degrees.
    NOTE: Do not damage the oil seal.
    Fig 8: Installing Right-Hand Halfshaft And Intermediate Shaft
    G02198826Courtesy of FORD MOTOR CO.
  9. Install the right-hand halfshaft and intermediate shaft.
  10. Install a new snap ring.
    Fig 9: Installing Snap Ring
    G02198827Courtesy of FORD MOTOR CO.
    11. CAUTION: To avoid damage to joints and boots, do not bent the inner halfshaft joint by more than 18 degrees, the outer one by more than 45 degrees.
    NOTE: Do not damage the oil seal. Check that the snap ring engages correctly.
    Fig 10: Installing Left-Hand Halfshaft
    G02198828Courtesy of FORD MOTOR CO.
  11. Install the left-hand halfshaft.
    12. CAUTION: Do not loosen the connector cooler inlet to the transaxle.
    Fig 11: Positioning And Installing Transaxle Lower Cooling Tube
    G02198829Courtesy of FORD MOTOR CO.
  12. Position and install the transaxle lower cooling tube.
    13. CAUTION: Do not loosen the connector cooler inlet to the transaxle.
    Fig 12: Positioning And Installing Transaxle Upper Cooling Tube
    G02198830Courtesy of FORD MOTOR CO.
  13. Position and install the transaxle upper cooling tube.
    14. NOTE: Do not tighten the bolt.
    Fig 13: Installing Right-Hand Roll Restrictor Center Bolt
    G02198831Courtesy of FORD MOTOR CO.
  14. Install the right-hand roll restrictor center bolt.
    15. WARNING: Support the subframe using Rotunda powertrain lift. Place a wooden block approximately one meter (40 inches) in length secured to the lift under the subframe.
    NOTE: Do not tighten the bolts at this stage.
    Fig 14: Installing Subframe
    G02198832Courtesy of FORD MOTOR CO.
  15. Install the subframe.
  16. Install the steering intermediate shaft.
    Fig 15: Installing Steering Intermediate Shaft
    G02198833Courtesy of FORD MOTOR CO.
  17. Install the transaxle cooler line brackets, and bolt.
    • Position the suction accumulator (A/C), if equipped.
      Fig 16: Installing Transaxle Cooler Line Brackets, And Bolt
      G02198834Courtesy of FORD MOTOR CO.
  18. Install the power steering hoses to the subframe (one nut and two bolts).
    Fig 17: Installing Power Steering Hoses To The Subframe
    G02198835Courtesy of FORD MOTOR CO.
  19. Using the special tool, install the steering gear (two bolts) (left-hand side shown).
    Fig 18: Installing Steering Gear (Two Bolts) (Left-Hand Side Shown)
    G02198836Courtesy of FORD MOTOR CO.
  20. Install the steering gear heat shield.
    Fig 19: Installing Steering Gear Heat Shield
    G02198837Courtesy of FORD MOTOR CO.
    Fig 20: Aligning Sub-Frame And Tightening Bolts
    G02198838Courtesy of FORD MOTOR CO.
  21. Using the special tool, align the sub-frame and tighten the bolts.
    1. Install the special tool.
    2. Align the subframe with the locating holes in the body.
    3. Install the subframe bolts working diagonally.
  22. Remove the left-hand support insulator and install the special tool.
    1. Install the special tool.
    2. Install the bolts.
    3. Install the through bolt.
      Fig 21: Installing Bolts
      G02198839Courtesy of FORD MOTOR CO.
  23. Lower the vehicle.
  24. Tighten the transaxle rear support bracket nuts.
    Fig 22: Tightening Transaxle Rear Support Bracket Nuts
    G02198840Courtesy of FORD MOTOR CO.
  25. Raise and support the vehicle.
  26. Tighten the right-hand support insulator through bolt.
    Fig 23: Tightening Right-Hand Support Insulator Through Bolt
    G02198841Courtesy of FORD MOTOR CO.
  27. Remove the special tool and install the left-hand support isolator.
    1. Install the through bolt.
    2. Install the bolts.
      Fig 24: Installing Bolts
      G02198842Courtesy of FORD MOTOR CO.
    28. CAUTION: Do not damage the boot or the ABS sensor ring.
  28. Connect the lower suspension arm ball joints and the stabilizer link rods.
    • Attach the ABS wiring harness bracket to the suspension strut.
      Fig 25: Connecting Lower Suspension Arm Ball Joints And Stabilizer Link Rods
      G02198843Courtesy of FORD MOTOR CO.
    29. CAUTION: Extreme extension of the flexible tube can lead to damage.
  29. Install the flexible tube and the rear three-way catalytic converter (TWC).
    • Install the new gaskets.
    • Remove the protection collar.
      Fig 26: Installing Flexible Tube And Rear Three-Way Catalytic Converter (TWC)
      G02198844Courtesy of FORD MOTOR CO.
  30. Install the flexible tube and the TWC to the exhaust manifold.
    • Install the gaskets.
      Fig 27: Installing Gaskets
      G02198845Courtesy of FORD MOTOR CO.
  31. Install the cable ties.
    Fig 28: Installing Cable Ties
    G02198846Courtesy of FORD MOTOR CO.

    Vehicles with air conditioning 

  32. Install the suction accumulator bracket bolts.
    Fig 29: Installing Suction Accumulator Bracket Bolts
    G02198847Courtesy of FORD MOTOR CO.

    All vehicles 

  33. Install the bumper brackets on both sides (left-hand side shown).
    Fig 30: Installing Bumper Brackets On Both Sides
    G02198848Courtesy of FORD MOTOR CO.
  34. Install the right-hand fender splash shield.
    Fig 31: Installing Right-Hand Fender Splash Shield
    G02198849Courtesy of FORD MOTOR CO.
  35. Install the radiator splash shield.
    • Install the bolts and clips.
      Fig 32: Installing Radiator Splash Shield
      G02198850Courtesy of FORD MOTOR CO.
  36. Install the both front wheels.
  37. Connect the selector cable from the transaxle.
    1. Selector lever selector cable
    2. Bracket
      Fig 33: Connecting Selector Cable From Transaxle
      G02198851Courtesy of FORD MOTOR CO.
  38. Connect the turbine shaft speed (TSS) sensor (shown from below).
    • Clip the cable.
      Fig 34: Connecting Turbine Shaft Speed (TSS) Sensor
      G02198852Courtesy of FORD MOTOR CO.
  39. Connect the output shaft speed (OSS) sensor connector.
    Fig 35: Connecting Output Shaft Speed (OSS) Sensor Connector
    G02198853Courtesy of FORD MOTOR CO.
    40. NOTE: Ground cable.
    Fig 36: Installing Upper Bellhousing Bolts
    G02198854Courtesy of FORD MOTOR CO.
  40. Install the upper bellhousing bolts.
  41. Remove the special tools.
    Fig 37: Removing Special Tools
    G02198855Courtesy of FORD MOTOR CO.
  42. Check that the selector lever position indicator agrees with the transaxle operation.
    • Parking lock in selector lever position "P", reverse gear in selector lever position "R" and forward in selector lever position "D".
      Fig 38: Checking Selector Lever Position Indicator Agrees With Transaxle Operation
      G02198856Courtesy of FORD MOTOR CO.
  43. If the selector lever position indicator does not agree with the transaxle operation in all settings:
    • Raise the vehicle and disconnect the head shield (four clips).
    44. NOTE: The mark line up in position "D". There is no need to hold after engaging a gear as there is an integral detent mechanism.
  44. Move the selector lever to position "D".
    1. Prevent the selector cable from turning.
    2. Disconnect the selector cable adjusting cap.
    3. Move the selector lever to position "D".
      Fig 39: Disconnecting Selector Cable Adjusting Cap
      G02198857Courtesy of FORD MOTOR CO.
  45. Adjust the selector lever scale position.
    • Remove the selector lever nuts.
    46. NOTE: The selector lever has it's own detent mechanism. Holding the selector lever is not necessary.
  46. Slide the whole selector assembly forwards or backwards until the reading on the scale and the position of the selector lever indicator corresponds.
  47. Tighten the selector lever nuts.
    Fig 40: Tightening Selector Lever Nuts
    G02198858Courtesy of FORD MOTOR CO.
    48. NOTE: The selector lever has its own detent mechanism. It is not necessary to hold in after engaging a gear.
    Fig 41: Moving Automatic Transaxle Selector Lever To Position "D"
    G02198859Courtesy of FORD MOTOR CO.
  48. Move the automatic transaxle selector lever to position "D".
  49. Lock the selector cable.
    1. Prevent the selector cable from turning.
    2. Lock the selector cable adjustment cap.
      • Fit the heat shield.
        Fig 42: Locking Selector Cable
        G02198860Courtesy of FORD MOTOR CO.
  50. Install the starter motor bolts.
    Fig 43: Installing Starter Motor Bolts
    G02198861Courtesy of FORD MOTOR CO.
  51. Install the water pump cover.
    • Attach the engine coolant hose and install the bolts.
      Fig 44: Installing Bolts
      G02198862Courtesy of FORD MOTOR CO.
  52. Connect the electrical connectors.
    1. Ground cable
    2. Automatic transaxle control
    3. Transmission range (TR) switch
    4. Wiring harness retaining clip
      Fig 45: Connecting Electrical Connectors
      G02198863Courtesy of FORD MOTOR CO.
    53. NOTE: Use an Allen key to prevent the piston rod from turning.
    Fig 46: Tightening Suspension Strut Locknuts On Both Sides
    G02198864Courtesy of FORD MOTOR CO.
  53. Tighten the suspension strut locknuts on both sides (right-hand side shown).
  54. Remove the radiator supports.
    Fig 47: Removing Radiator Supports
    G02198865Courtesy of FORD MOTOR CO.
  55. Fill the transaxle with automatic transmission fluid.
    Fig 48: Filling Transaxle With Automatic Transmission Fluid
    G02198866Courtesy of FORD MOTOR CO.
    56. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.
  56. Install the battery tray.
  57. Fill and bleed the power steering system. Refer to STEERING SYSTEM - GENERAL INFORMATION .
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