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Section 1732 (Manual Transaxle/Transmission): Installation: Transaxle

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.
SPECIAL TOOL(S)

G04682330Courtesy of FORD MOTOR CO.
 Three-Bar Engine Support Kit
303-F072 or equivalent
G04682331Courtesy of FORD MOTOR CO.
 Hi-Lift Jack
014-00942
MATERIAL

Item Specification
Premium Long-Life Grease XG-1-C or XG-1-K (US); CXG-1-C (Canada) ESA-M1C75-B
SAE 75W-90 Premium Gear Oil XY-75W90-QGL WSS-M2C203-A1
  1. Apply a very small amount of grease on the input shaft splines.
    • Wipe off excess grease. The splines should have a thin film of grease only. Excess grease can contaminate the clutch facing and affect clutch function.
    2. WARNING: Secure the transaxle to the transmission jack with a safety strap.
  2. Raise and position the transaxle to the engine.
  3. Install the bellhousing-to-oil pan bolt.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 1: Locating Bellhousing-To-Oil Pan Bolt
      G04682332Courtesy of FORD MOTOR CO.
  4. Install the 2 oil pan-to-bellhousing bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 2: Locating Oil Pan-To-Bellhousing Bolts
      G04682333Courtesy of FORD MOTOR CO.
  5. Install the 7 remaining transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
  6. Install the transmission lower mount to the transaxle. Do not tighten the bolts at this time.
  7. Position the slave cylinder to the clutch release arm and install the bolts.
    • Tighten to 20 Nm (15 lb-ft).
      Fig 3: Locating Bolts
      G04682334Courtesy of FORD MOTOR CO.
  8. Install the clutch tube bracket bolts.
    • Tighten to 22 Nm (16 lb-ft).
      Fig 4: Locating Clutch Tube Bracket Bolts
      G04682335Courtesy of FORD MOTOR CO.
  9. Tighten the starter motor bolts to specification.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 5: Locating Starter Motor Bolts
      G04682336Courtesy of FORD MOTOR CO.
  10. Remove the transmission jack.
    Fig 6: Identifying Transmission Jack
    G04682337Courtesy of FORD MOTOR CO.
    11. NOTE: Install a new stub shaft circlip.
  11. Install the LH halfshaft into the transaxle.
    12. NOTE: Install a new stub shaft circlip.
    Fig 7: Locating Intermediate Shaft Support Bracket Bolts
    G04682338Courtesy of FORD MOTOR CO.
  12. Install the RH intermediate shaft into the transaxle. Install the 2 intermediate shaft support bracket bolts.
  13. Install the roll restrictor mount bracket.
  14. Install the front subframe. For additional information, refer to UNI-BODY, SUBFRAME AND MOUNTING SYSTEM .
  15. Remove the lift table.
  16. Install the engine roll-restrictor.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 8: Locating Bolts And Engine Roll-Restrictor
      G04682339Courtesy of FORD MOTOR CO.
  17. Connect the reverse lamp switch electrical connector.
  18. Connect the vehicle speed sensor (VSS) electrical connector.
    Fig 9: Locating VSS Electrical Connector
    G04682340Courtesy of FORD MOTOR CO.
  19. Working in the engine compartment, position the transaxle lower mount to the upper mount and install the 2 bolts. Tighten all 5 bolts to specification.
    • Tighten to 80 Nm (59 lb-ft).
      Fig 10: Locating Bolts
      G04682341Courtesy of FORD MOTOR CO.
  20. Install the ground wire and ground wire bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 11: Locating Ground Wire Bolt
      G04682342Courtesy of FORD MOTOR CO.
  21. Install the radio frequency interference capacitor, the ground cable and the bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 12: Locating Radio Frequency Interference Capacitor, Ground Cable And Bolt
      G04682343Courtesy of FORD MOTOR CO.
  22. Install the 3 upper transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
  23. Attach the wire harness to the transaxle.
  24. Remove the special tool.
    Fig 13: Identifying Special Tool
    G04682344Courtesy of FORD MOTOR CO.
  25. Install the shift and selector cables. Make sure the cables are engaged in the shift bracket and the spring clips are seated in the groove.
    Fig 14: Locating Shift Bracket And Spring Clips
    G04682345Courtesy of FORD MOTOR CO.
  26. Install battery tray and the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  27. Install the air cleaner assembly. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING - 2.3L .
  28. Fill the transaxle with the specified fluid.
  29. Install the splash shield and the 7 bolts, if equipped.
    Fig 15: Locating Splash Shield And Bolts
    G04682346Courtesy of FORD MOTOR CO.
  30. Check the vehicle for normal operation.
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