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Section 1768 (Automatic Transaxle/Transmission - FNR5): Installation: Transaxle: Installation

WARNING: This page is about a different car, the 2006 Mercury Milan and 2006 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
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 .
  1. Make sure that the torque converter is installed correctly.
    2. NOTE: Lubricate the torque converter pilot hub with multi-purpose grease.
  2. 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 1: Identifying Installation Depth Between Transaxle Flange And Torque Converter
      G04681911Courtesy of FORD MOTOR CO.
  3. Using a high-lift jack, secure the transaxle using a safety strap.
  4. Remove the special tool.
    Fig 2: Identifying Special Tool
    G04681912Courtesy of FORD MOTOR CO.
    5. NOTE: Make sure that the dowel pins are installed in the engine block prior to installing the transaxle.
  5. Move the transaxle into position.
    6. NOTE: Note the location of the different length bolts.
  6. Install the 3 front torque converter housing bolts.
    • Tighten to 47 Nm (35 lb-ft).
      Fig 3: Locating Front Torque Converter Housing Bolts
      G04681913Courtesy of FORD MOTOR CO.
  7. Install the 3 rear converter housing bolts.
    • Tighten to 47 Nm (35 lb-ft).
      Fig 4: Locating Rear Converter Housing Bolts
      G04681914Courtesy of FORD MOTOR CO.
  8. Remove the transmission jack.
  9. Install the bracket and the nut on the torque converter housing stud.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 5: Locating Torque Converter Housing Stud Nut
      G04681915Courtesy of FORD MOTOR CO.
    10. CAUTION: Rotate the engine in a clockwise direction only or engine damage will occur.
    NOTE: Install new self-locking nuts only.
  10. Install new torque converter nuts.
    • Tighten to 37 Nm (27 lb-ft).
      Fig 6: Locating Torque Converter Nuts
      G04681916Courtesy of FORD MOTOR CO.
  11. Connect the transmission fluid cooler hoses to the transmission.
    Fig 7: Locating Transmission Fluid Cooler Hoses
    G04681917Courtesy of FORD MOTOR CO.
  12. Position the starter in place and install the 2 bolts.
    • Tighten to 35 Nm (26 lb-ft).
      Fig 8: Locating Starter Nuts
      G04681918Courtesy of FORD MOTOR CO.
  13. Install the wiring harness fastener on the starter stud.
    Fig 9: Locating Starter Wiring Harness Fastener
    G04681919Courtesy of FORD MOTOR CO.
  14. Install the starter terminals and install the boot back into position.
    1. Tighten to 12 Nm (9 lb-ft).
    2. Tighten to 5 Nm (44 lb-in).
      Fig 10: Locating Starter Terminal Bolts
      G04681920Courtesy of FORD MOTOR CO.
  15. Position the subframe in place using a suitable powertrain lift.
    16. NOTE: LH shown, RH similar.
  16. Install the front subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
      Fig 11: Locating Front Subframe Nut
      G04681921Courtesy of FORD MOTOR CO.
  17. Position the subframe support brackets in place and loosely install the bolts.
    Fig 12: Locating Subframe Support Brackets And Bolts
    G04681922Courtesy of FORD MOTOR CO.
  18. Install the rear subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
      Fig 13: Locating Rear Subframe Nut
      G04681923Courtesy of FORD MOTOR CO.
  19. Tighten the subframe support bracket bolts.
    • Tighten to 103 Nm (76 lb-ft).
      Fig 14: Locating Subframe Support Bracket And Bolts
      G04681924Courtesy of FORD MOTOR CO.
  20. Install the LH halfshaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
  21. Remove the tool installed during removal of the transaxle to hold the differential side gears.
    Fig 15: Locating Differential Side Gear Hole
    G04681925Courtesy of FORD MOTOR CO.
  22. Install the RH halfshaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
    23. NOTE: LH shown, RH similar.
  23. Install the sway bar links and nuts to the struts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 16: Locating Sway Bar Links Nut
      G04681926Courtesy of FORD MOTOR CO.
  24. Position the steering gear in place and install the bolts.
    • Tighten to 107 Nm (79 lb-ft).
      Fig 17: Locating Steering Gear Bolts
      G04681927Courtesy of FORD MOTOR CO.
  25. Install the RH power steering tube bracket bolt.
    • Tighten to 9 Nm (80 lb-in).
      Fig 18: Locating RH Power Steering Tube Bracket Bolt
      G04681928Courtesy of FORD MOTOR CO.
  26. Install the 2 LH power steering tube bracket bolts.
    • Tighten to 9 Nm (80 lb-in).
      Fig 19: Locating LH Power Steering Tube Bracket Bolts
      G04681929Courtesy of FORD MOTOR CO.
  27. Install the LH power steering tube bracket bolt.
    • Tighten to 9 Nm (80 lb-in).
      Fig 20: Locating LH Power Steering Tube Bracket Bolt
      G04681930Courtesy of FORD MOTOR CO.
  28. Position the LH front structure-to-subframe splash shield in place and install the 6 pin-type retainers.
    Fig 21: Locating LH Front Structure-To-Subframe Splash Shield
    G04681931Courtesy of FORD MOTOR CO.
  29. Position the LH splash shield in place and install the 4 screws.
    Fig 22: Locating LH Splash Shield Screws
    G04681932Courtesy of FORD MOTOR CO.
  30. Position the RH front structure-to-subframe splash shield in place and install the 6 pin-type retainers.
    Fig 23: Locating RH Front Structure-To-Subframe Splash Shield
    G04681933Courtesy of FORD MOTOR CO.
  31. Position the RH splash shield in place and install the 4 screws.
    Fig 24: Locating RH Splash Shield Screws
    G04681934Courtesy of FORD MOTOR CO.
  32. Connect the output shaft speed (OSS) sensor electrical connector.
    Fig 25: Locating Output Shaft Speed (OSS) Sensor Electrical Connector
    G04681935Courtesy of FORD MOTOR CO.
  33. Connect the pressure switch electrical connector.
    Fig 26: Locating Pressure Switch Electrical Connector
    G04681936Courtesy of FORD MOTOR CO.
  34. Position the transaxle support insulator bracket in place and install the 3 nuts.
    • Tighten to 80 Nm (59 lb-ft).
      Fig 27: Locating Transaxle Support Insulator Bracket And Nuts
      G04681937Courtesy of FORD MOTOR CO.
  35. Raise the transaxle and install the 2 transaxle insulator bolts.
    • Tighten to 63 Nm (46 lb-ft).
      Fig 28: Locating Transaxle Insulator Bolts
      G04681938Courtesy of FORD MOTOR CO.
  36. Install the 2 roll restrictor bracket bolts.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 29: Locating Roll Restrictor Bracket Bolts
      G04681939Courtesy of FORD MOTOR CO.
  37. Install the 3 top torque converter housing bolts.
    • Tighten to 47 Nm (35 lb-ft).
      Fig 30: Locating Torque Converter Housing Bolts
      G04681940Courtesy of FORD MOTOR CO.
  38. Install the ground strap.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 31: Locating Ground Strap
      G04681941Courtesy of FORD MOTOR CO.
  39. Connect the turbine shaft speed (TSS) sensor, intermediate shaft speed sensor and the 5th gear valve body electrical connectors.
    Fig 32: Locating Turbine Shaft Speed (TSS) Sensor, Intermediate Shaft Speed Sensor And 5Th Gear Valve Body Electrical Connectors
    G04681942Courtesy of FORD MOTOR CO.
  40. Connect the main valve body and the transmission range (TR) sensor electrical connectors and connect the wiring harness to the transmission.
    Fig 33: Locating Valve Body And Transmission Range (TR) Sensor Electrical Connectors And Connect Wiring Harness To Transmission
    G04681943Courtesy of FORD MOTOR CO.
  41. Position the selector lever cable and bracket in place, and connect the electrical harness fastener and install the 2 bolts.
    • Tighten to 20 Nm (15 lb-ft).
      Fig 34: Locating Electrical Harness Fastener, Bolts And Bracket
      G04681944Courtesy of FORD MOTOR CO.
  42. Connect the selector lever cable end to the manual lever.
    Fig 35: Locating Selector Lever Cable End
    G04681945Courtesy of FORD MOTOR CO.
  43. Install the battery tray.
    1. Position the battery tray in place and install the bolt.
      • Tighten to 9 Nm (80 lb-in).
    2. Install the nut.
      • Tighten to 9 Nm (80 lb-in).
    3. Connect the 3 wiring harness retainers.
    4. Connect the positive battery cable fastener to the battery tray.
      Fig 36: Identifying Battery Tray Nut, Bolt, Positive Battery Cable Fastener And Wiring Harness Retainer
      G04681946Courtesy of FORD MOTOR CO.
    44. 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 to relearn the strategy.
  44. Install the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  45. Fill the transaxle with clean automatic transmission fluid.
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