Automatic Transmission: Installation: Transaxle

Special Tool(s) 

Fig 1: Identifying Special Tools

Courtesy of FORD MOTOR CO.

1. If installing a new or remanufactured transaxle, install the roll restrictor bracket.
   Fig 2: Roll Restrictor Bracket Bolts Torque Specification

   Courtesy of FORD MOTOR CO.
2. Install the special tool.
   Fig 3: Installing Special Tool

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3. Position the transaxle in place.
   Fig 4: Positioning Transaxle In Place

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4. Remove the special tool.
   Fig 5: Removing Special Tool

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5. Move the transaxle assembly toward the engine assembly and install the bolt.
   Fig 6: Bolt Torque Specifications Table (1 Of 3)

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6. Install the bolt.
   Fig 7: Bolt Torque Specifications Table (2 Of 3)

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7. Install the bolts.
   Fig 8: Bolt Torque Specifications Table (3 Of 3)

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8. Remove the transmission jack.
9. Install the fluid cooler line.
   Fig 9: Installing Fluid Cooler Line

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10. Install the OSS sensor.
    Fig 10: Installing OSS Sensor

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11. Install the fluid cooler tube.
    1. Install the fluid cooler tube.
    2. Install the bolt.
    3. Connect the output shaft speed (OSS) sensor.
    4. Connect the turbine shaft speed (TSS) sensor (white connector).
    Fig 11: Installing Fluid Cooler Tube

    Courtesy of FORD MOTOR CO.
12. Install four flexplate nuts.
    Fig 12: Flexplate Nut Torque Specification

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13. Install the access cover.
    Fig 13: Installing Access Cover

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14. Connect the main control cover vent tube.
    Fig 14: Connecting Main Control Cover Vent Tube

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15. Lower the vehicle.
16. Raise the transaxle enough to install the cross brace.
    Fig 15: Installing Cross Brace

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17. Raise and support the vehicle. For additional information, refer to JACKING & LIFTING .
18. Install the transfer case unit and install one bolt.
    Fig 16: Transfer Case Unit Bolt Torque Specification

    Courtesy of FORD MOTOR CO.
19. Install the transfer case bolts.
    Fig 17: Transfer Case Bolts Torque Specification

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20. Install the cross brace.
    Fig 18: Cross Brace Bolts Torque Specification

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21. Install the crossmember dampener.
    Fig 19: Crossmember Dampener Nut Torque Specification

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22. Install the transfer case bracket.
    Fig 20: Transfer Case Bracket Bolts Torque Specification

    Courtesy of FORD MOTOR CO.
23. Install the RH exhaust manifold. For additional information, refer to ENGINE-3.0L (4V) .
24. Install the rear driveshaft. For additional information, refer to DRIVESHAFT .
25. Install the exhaust pipe, and connect the exhaust pipe flange.
    Fig 21: Installing Exhaust Pipe, And Connecting Exhaust Pipe Flange

    Courtesy of FORD MOTOR CO.
26. Connect the front flange.
    Fig 22: Front Flange Bolt Torque Specification

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27. Install the exhaust pipe.
    1. Install the pipe, and install the bolts.
    2. Install the rubber hanger.
    3. Remove the special tool.
    Fig 23: Installing Exhaust Pipe

    Courtesy of FORD MOTOR CO.
28. Reconnect the HO2S sensor wire to the oil pan bolt studs and connect the connector.
    Fig 24: Reconnecting HO2S Sensor Wire To Oil Pan Bolt Studs

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29. Install the cross brace.
    Fig 25: Cross Brace Bolt Torque Specification

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CAUTION: Align the mounting bracket studs and the intermediate shaft bearing bracket holes with the marks made during removal.
30. Install the LH, RH halfshaft and intermediate shaft assembly. For additional information, refer to FRONT DRIVE HALFSHAFTS .
31. Install the two splash shields.
    Fig 26: Splash Shield Bolts Torque Specifications

    Courtesy of FORD MOTOR CO.
32. Lower the engine onto the RH engine mount.
    Fig 27: Lowering Engine Onto RH Engine Mount

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33. Install the bolt for the RH engine mount.
    Fig 28: Installing Bolt For RH Engine Mount

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34. Install the rear transaxle mount.
    Fig 29: Installing Rear Transaxle Mount

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35. Install the transaxle mount assembly.
    Fig 30: Installing Transaxle Mount Assembly

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36. Install the bolts.
    Fig 31: Bolt Torque Specifications

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37. Remove the special tool.
    Fig 32: Removing Special Tool (1 Of 3)

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38. Remove the special tool.
    Fig 33: Removing Special Tool (2 Of 3)

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39. Remove the special tool.
    Fig 34: Removing Special Tool (3 Of 3)

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40. Connect the electrical connectors to the upper intake.
    Fig 35: Connecting Electrical Connectors To Upper Intake

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41. Install the starter motor, and install two bolts.
    Fig 36: Starter Motor Bolt Torque Specification

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42. Install the ground cable.
    Fig 37: Installing Ground Cable

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43. Install the starter motor harness connector.
    Fig 38: Installing Starter Motor Harness Connector

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44. Install the shift cable and bracket.
    Fig 39: Shift Cable Bracket Bolts Torque Specification

    Courtesy of FORD MOTOR CO.
45. Install the wire harness clip to the shift cable bracket.
    Fig 40: Installing Wire Harness Clip To Shift Cable Bracket

    Courtesy of FORD MOTOR CO.
46. Connect the shift cable.
    Fig 41: Connecting Shift Cable

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47. Connect the wire harness.
    Fig 42: Connecting Wire Harness

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48. Install the wire harness bracket, and connect the transaxle harness connector.
    Fig 43: Installing Wire Harness Bracket, And Connecting Transaxle Harness Connector

    Courtesy of FORD MOTOR CO.
49. Connect the vent hose to the transmission filler tube bracket.
    Fig 44: Connecting Vent Hose To Transmission Filler Tube Bracket

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50. Connect the HO2S sensor.
    Fig 45: Connecting HO2S Sensor

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51. Connect the two HO2S sensors.
    Fig 46: Connecting Two HO2S Sensors

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52. Connect the transmission range (TR) sensor.
    Fig 47: Connecting Transmission Range (TR) Sensor

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NOTE: If installing an exchange assembly, the digital TR sensor must be aligned.
Fig 48: Aligning Digital TR Sensor
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53. Using the special tool, align the digital TR sensor.
54. Install the air cleaner assembly.
    Fig 49: Installing Air Cleaner Assembly

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55. Install the intake tube and air cleaner cover.
    Fig 50: Installing Intake Tube And Air Cleaner Cover

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56. Connect the breather tube and mass air flow (MAF) sensor.
    Fig 51: Connecting Breather Tube And Mass Air Flow (MAF) Sensor

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NOTE: Before installing the battery tray, check the vent tube hose for any obstructions, kinks or incorrect routing position.
57. Install the battery and tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .