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Automatic Transmission: Installation: Transaxle: Installation

All vehicles 

CAUTION: Prior to installation of a new or overhauled transaxle, the transmission fluid cooler tubes must be cleaned, otherwise transaxle failure can occur.
NOTE: Prior to installation of a new or overhauled transaxle, flush out the cooler and cooler lines. For additional information, refer to Transmission Fluid Cooler Backflushing and Cleaning .
  1. Inspect the transmission fluid cooler tube backing rings and seals for damage and install a new backing rings or seals if necessary. Lubricate the transmission fluid cooler tube seals with clean automatic transmission fluid and install the backing rings and seals on the transmission fluid cooler tube.
    Item Part Number Description
    1 7D285 Seal
    2 7J324 Backing ring
    2. Fig 1: Identifying Transmission Fluid Cooler Tube Backing Ring & Seal
    GF0031666Courtesy of FORD MOTOR CO.
  2. Position the transmission fluid cooler thermal bypass valve and transmission fluid cooler tube assembly in place and install the 2 nuts.
    • Tighten to 9 Nm (80 lb-in).
    3. Fig 2: Identifying Transmission Fluid Cooler Tube Assembly & Nuts
    GF0031964Courtesy of FORD MOTOR CO.
  3. Install 2 new transmission fluid cooler tube bolts.
    • Tighten to 9 Nm (80 lb-in).
    4. Fig 3: Locating transmission fluid cooler tube bolt
    GF0031716Courtesy of FORD MOTOR CO.
  4. Lubricate the torque converter pilot hub with grease.
    5. CAUTION: If the transaxle is not positioned on the dowel pins, damage to the transaxle can occur.
  5. If the dowel pins were pulled out of the engine block during removal, install new dowel pins in the engine block.
    6. Fig 4: Locating dowel pin from torque converter housing
    GF0031715Courtesy of FORD MOTOR CO.
  6. Position the transaxle in place and install the 7 torque converter housing bolts.
    • Tighten to 48 Nm (35 lb-ft).
    7. Fig 5: Locating torque converter housing bolts
    GF0031714Courtesy of FORD MOTOR CO.
  7. Remove the special tool from the transaxle.
    8. Fig 6: Supporting Transaxle Using Special Tool (209-00152) & A Suitable Transmission Jack
    GF0031713Courtesy of FORD MOTOR CO.
  8. Install the transmission fluid cooler tubes in the transmission fluid cooler thermal bypass valve.
    9. Fig 7: Locating Transmission Fluid Cooler Tubes
    GF0031423Courtesy of FORD MOTOR CO.
  9. Install the 2 secondary latches on the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.
    10. Fig 8: Locating Secondary Latches From Transmission Fluid Cooler Tubes
    GF0031391Courtesy of FORD MOTOR CO.
  10. Install 3 new torque converter bolts.
    • Tighten to 55 Nm (41 lb-ft).
    11. Fig 9: Locating Torque Converter Bolts
    GF0031394Courtesy of FORD MOTOR CO.
  11. Install the inspection cover and the 2 fasteners.
    12. Fig 10: Locating Oil Fasteners On Inspection Cover
    GF0031393Courtesy of FORD MOTOR CO.

    All wheel drive (AWD) vehicles 

  12. Position the power transfer unit (PTU) in place and install the 5 bolts.
    • Tighten to 90 Nm (66 lb-ft).
    13. Fig 11: Identifying PTU & Bolts
    GF0031403Courtesy of FORD MOTOR CO.
  13. Position the PTU support bracket in place and install the 5 bolts.
    • Tighten to 70 Nm (52 lb-ft).
    14. Fig 12: Locating Power Transfer Unit (PTU) Support Bracket & Bolts
    GF0029153Courtesy of FORD MOTOR CO.
  14. Position the RH catalytic converter in place and install the 4 nuts.
    • Tighten to 40 Nm (30 lb-ft).
    15. Fig 13: Locating RH Catalytic Converter Nuts
    GF0031712Courtesy of FORD MOTOR CO.
  15. Install the 2 RH catalytic converter support bracket bolts.
    • Tighten to 20 Nm (15 lb-ft).
    16. Fig 14: Locating Catalytic Converter Support Bracket Bolts
    GF0031672Courtesy of FORD MOTOR CO.
  16. Connect the RH catalyst monitor electrical connector.
    17. Fig 15: Identifying RH Catalyst Monitor Electrical Connector
    GF0031711Courtesy of FORD MOTOR CO.
  17. Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal and install the 4 bolts.
    • Tighten to 70 Nm (52 lb-ft).
    18. Fig 16: Locating Driveshaft Aside Bolts
    GF0031396Courtesy of FORD MOTOR CO.
  18. Using a suitable driver, install a new intermediate shaft seal.
    • Make sure that the seal is fully seated against the drive gear.
    19. NOTE: Do not overheat (melt) the seal deflector. If the deflector is damaged, a new one must be used.
  19. Using a suitable heat gun, heat the new seal deflector. Concentrate the heat across the back of the deflector near the white colored tabs. Install the seal deflector immediately after heating.
    • If necessary, use special tools 308-430 and 308-431 to seat the deflector. Make sure the deflector is fully seated and there are no cracks on the face or inner diameter white colored tabs.
    20. Fig 17: Identifying Seal Deflector
    GF0029667Courtesy of FORD MOTOR CO.

    All vehicles 

  20. Position the roll restrictor bracket on the transaxle and install the 3 bolts.
    • Tighten to 90 Nm (66 lb-ft).
    21. Fig 18: Locating Transaxle Bracket Bolts
    GF0031347Courtesy of FORD MOTOR CO.
  21. Position the subframe in place and install the 2 middle nuts.
    • Tighten to 150 Nm (111 lb-ft).
    22. Fig 19: Locating Middle Subframe Nuts
    GF0031313Courtesy of FORD MOTOR CO.
  22. Install the 2 front subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
    23. Fig 20: Locating Front Subframe Nuts
    GF0031312Courtesy of FORD MOTOR CO.
  23. Position the subframe support brackets in place and loosely install the bolts.
    24. Fig 21: Locating Subframe Support Brackets And Bolts
    GF0029660Courtesy of FORD MOTOR CO.
  24. Install the rear subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
    25. Fig 22: Locating Rear Subframe Nuts
    GF0029659Courtesy of FORD MOTOR CO.
  25. Tighten the subframe support bracket bolts.
    • Tighten to 103 Nm (76 lb-ft).
    26. Fig 23: Locating Subframe Support Brackets And Bolts
    GF0029660Courtesy of FORD MOTOR CO.
  26. Position the roll restrictor in place, install the bracket and the 3 bolts.
    • Tighten to 90 Nm (66 lb-ft).
    27. Fig 24: Locating Roll Restrictor-To-Transaxle Bracket Plate Bolts
    GF0031345Courtesy of FORD MOTOR CO.
  27. Install the roll restrictor heat shield and the 2 nuts.
    • Tighten to 11 Nm (8 lb-ft).
    28. Fig 25: Locating Roll Restrictor Heat Shield Nuts
    GF0031344Courtesy of FORD MOTOR CO.
  28. Position the stabilizer bar in place and install the 4 bolts.
    • Tighten to 48 Nm (35 lb-ft).
    29. Fig 26: Locating Stabilizer Bar & Bolts
    GF0031308Courtesy of FORD MOTOR CO.
  29. Position the power steering rack in place and install the 4 bolts.
    • Tighten to 107 Nm (79 lb-ft).
    30. Fig 27: Locating Steering Rack Bolts
    GF0031710Courtesy of FORD MOTOR CO.
  30. Position the exhaust Y-pipe assembly in place and install the 4 nuts.
    • Tighten to 40 Nm (30 lb-ft).
    31. Fig 28: Locating Exhaust Flexible Pipe, Y-Pipe & Nuts
    GF0031306Courtesy of FORD MOTOR CO.
  31. Install the 2 exhaust hangers and tighten the exhaust clamp.
    • Tighten to 40 Nm (30 lb-ft).
    32. Fig 29: Locating Exhaust Flexible Pipe Clamp & Exhaust Hangers
    GF0031305Courtesy of FORD MOTOR CO.
  32. Position the LH halfshaft in the transaxle and in the steering knuckle.

    33. Front wheel drive (FWD) vehicles 

  33. Position the RH halfshaft and intermediate shaft support bracket in the transaxle and in the steering knuckle. Install 1 stud bolt and 1 bolt.
    • Tighten to 55 Nm (41 lb-ft).
    34. Fig 30: Locating Stud Bolts & RH Halfshaft/Intermediate Shaft Assembly
    GF0031402Courtesy of FORD MOTOR CO.
  34. Position the catalytic converter support bracket in place and install the bolt and the nut.
    1. Tighten the nut to 40 Nm (30 lb-ft).
    2. Tighten the bolt to 55 Nm (41 lb-ft).
    35. Fig 31: Locating Catalytic Converter Bracket Bolt & Nut
    GF0031422Courtesy of FORD MOTOR CO.
  35. Install the 2 RH catalytic converter support bracket bolts.
    • Tighten to 20 Nm (15 lb-ft).
    36. Fig 32: Locating Catalytic Converter Support Bracket Bolts
    GF0031672Courtesy of FORD MOTOR CO.
  36. Install the steering rack heat shield and the 2 bolts.
    • Tighten to 6 Nm (53 lb-in).
    37. Fig 33: Locating Power Steering Rack Heat Shield Bolts
    GF0031709Courtesy of FORD MOTOR CO.

    AWD vehicles 

  37. Install the RH halfshaft and install the RH halfshaft bearing support bracket bolts.
    • Tighten to 23 Nm (17 lb-ft).
    38. Fig 34: Locating RH Halfshaft Bearing Support Bracket Bolts
    GF0028972Courtesy of FORD MOTOR CO.

    All vehicles 

    NOTE: RH side shown, LH side similar.
  38. Install the ball joints in the steering knuckles and install the pinch bolts.
    • Tighten to 55 Nm (41 lb-ft).
    39. Fig 35: Locating Ball Joint Pinch Bolt
    GF0031304Courtesy of FORD MOTOR CO.
    NOTE: RH side shown, LH side similar.
  39. Install the halfshaft nuts.
    • Tighten to 350 Nm (258 lb-ft).
    40. Fig 36: Locating RH Front Halfshaft Nut
    GF0031348Courtesy of FORD MOTOR CO.
    NOTE: RH side shown, LH side similar.
  40. Position the sway bar links in the lower control arms and install the nuts.
    • Tighten to 55 Nm (41 lb-ft).
    41. Fig 37: Locating Stabilizer Bar Link Nut
    GF0031349Courtesy of FORD MOTOR CO.
  41. Position the power steering tube in place on the RH side of the subframe and install the power steering tube bracket bolts.
    • Tighten to 5 Nm (44 lb-in).
    42. Fig 38: Identifying Power Steering Tube Bracket Bolts
    GF0031708Courtesy of FORD MOTOR CO.
  42. Position the lower bumper on the subframe and install the 3 LH nuts.
    • Tighten to 10 Nm (89 lb-in).
    43. Fig 39: Locating LH Subframe-To-Lower Bumper Nuts
    GF0031301Courtesy of FORD MOTOR CO.
  43. Install the 3 RH lower bumper-to-subframe nuts.
    • Tighten to 10 Nm (89 lb-in).
    44. Fig 40: Locating RH Subframe-To-Lower Bumper Nuts
    GF0031300Courtesy of FORD MOTOR CO.
  44. Install the front splash shield and install the 7 screws and the 3 push pin fasteners.
    45. Fig 41: Locating Push Pin Fasteners & Front Splash Shield Screws
    GF0031299Courtesy of FORD MOTOR CO.
  45. Install the RH splash shield.
    1. Install the screws.
    2. Install the push pin fasteners.
    46. Fig 42: Locating Push Pin Fasteners & RH Splash Shield
    GF0031707Courtesy of FORD MOTOR CO.
  46. Install the transaxle support insulator bracket, install the bolt and the 3 nuts.
    • Tighten to 63 Nm (46 lb-ft).
    47. Fig 43: Identifying Transaxle Support Insulator Bracket, Nuts & Bolts
    GF0031406Courtesy of FORD MOTOR CO.
  47. Install the transaxle support insulator through bolt.
    • Tighten to 175 Nm (129 lb-ft).
    48. Fig 44: Identifying Transaxle Support Insulator Bolt
    GF0031405Courtesy of FORD MOTOR CO.
  48. Remove the special tools.
    49. Fig 45: Removing Special Tools (303-290A, 303-290A-01, 303-290A-03A, 303-290A-12, 303-1246)
    GF0031706Courtesy of FORD MOTOR CO.
  49. Remove the special tools from the LH cylinder head.
    50. Fig 46: Removing Special Tool (303-1245) From LH Cylinder Head
    GF0029677Courtesy of FORD MOTOR CO.
  50. If a new solenoid body was installed, wipe the surface of the existing solenoid body strategy tag on top of the transaxle case clean and install the new solenoid body strategy tag (supplied with the solenoid body service kit) over it.
    51. Fig 47: Installing New Solenoid Body Strategy Tag Over Existing Solenoid Body Strategy Tag
    GF0031696Courtesy of FORD MOTOR CO.
  51. Install the fluid filler tube and the nut.
    • Tighten to 11 Nm (8 lb-ft).
    52. Fig 48: Identifying Transmission Fluid Filler Tube
    GF0031643Courtesy of FORD MOTOR CO.
  52. Install the transmission fluid level indicator.
    53. Fig 49: Identifying Transmission Fluid Level Indicator
    GF0031642Courtesy of FORD MOTOR CO.
  53. Route the coolant hoses in the transmission fluid filler tube.
    54. Fig 50: Identifying Coolant Hoses From Transmission Fluid Filler Tube
    GF0031641Courtesy of FORD MOTOR CO.
  54. Install the top 4 torque converter housing bolts.
    • Tighten to 48 Nm (35 lb-ft).
    55. Fig 51: Locating Torque Converter Housing Bolts
    GF0031705Courtesy of FORD MOTOR CO.
  55. Connect the transaxle electrical connector.
    56. Fig 52: Identifying Transaxle Control Electrical Connector
    GF0031384Courtesy of FORD MOTOR CO.
  56. Position the fuel hose routing clip on the transaxle stud.
    57. Fig 53: Identifying Fuel Hose Routing Clip From Transaxle Stud
    GF0031388Courtesy of FORD MOTOR CO.
  57. Install the starter and the 2 bolts.
    • Tighten to 26 Nm (19 lb-ft).
    58. Fig 54: Identifying Bolt, Stud Bolt & Starter
    GF0031409Courtesy of FORD MOTOR CO.
  58. Install the wiring harness fastener on the starter motor stud bolt.
    59. Fig 55: Identifying Wiring Harness Retainer From Starter Motor Stud Bolt
    GF0031408Courtesy of FORD MOTOR CO.
  59. Connect the starter motor terminals and position the starter terminal boot over the battery cable terminal.
    1. Tighten to 12 Nm (9 lb-ft).
    2. Tighten to 6 Nm (53 lb-in).
    60. Fig 56: Identifying Starter Motor Wire Terminals & Nuts
    GF0029337Courtesy of FORD MOTOR CO.
  60. Install the starter motor electrical terminal cover.
    61. Fig 57: Locating Starter Motor Electrical Terminal Cover
    GF0031704Courtesy of FORD MOTOR CO.
  61. Position the selector lever cable and bracket in place and install the 3 bolts.
    • Tighten to 12 Nm (9 lb-ft).
    62. Fig 58: Identifying Selector Lever Cable Bracket Bolts
    GF0031703Courtesy of FORD MOTOR CO.
  62. Place the selector lever in DRIVE.
    63. Fig 59: Placing Selector Lever In Drive
    GF0031965Courtesy of FORD MOTOR CO.
  63. Place the manual control lever in DRIVE.
    1. Rotate the manual control lever clockwise until it stops.
    2. Rotate the manual control lever counterclockwise one detent until it stops.
    64. Fig 60: Rotating Manual Control Lever Clockwise & Counterclockwise
    GF0031966Courtesy of FORD MOTOR CO.
  64. Unlock the selector lever cable adjuster.
    1. Pry the latch up.
    2. Push the lock tab to slide it over.
    65. Fig 61: Pushing Lock Tab To Slide It Over
    GF0031967Courtesy of FORD MOTOR CO.
  65. Slide the cable end forward or backward to align it with the manual control lever.
    66. Fig 62: Sliding Cable End Forward Or Backward To Align It With Manual Control Lever
    GF0031968Courtesy of FORD MOTOR CO.
  66. With the adjuster locking tab released, connect the selector lever cable end to the manual control lever.
    67. Fig 63: Connecting Selector Lever Cable End To Manual Control Lever With Adjuster Locking Tab Released
    GF0031969Courtesy of FORD MOTOR CO.
  67. Slide the release tab back to lock the adjuster.
    68. Fig 64: Sliding Release Tab Back To Lock Adjuster
    GF0031970Courtesy of FORD MOTOR CO.
  68. Install the upper intake manifold. For additional information, refer to ENGINE - 3.5L .
  69. Install the battery tray.
    1. Install the 3 bolts.
      • Tighten to 10 Nm (89 lb-in).
    2. Connect the wiring harness fasteners to the battery tray.
    70. Fig 65: Identifying Wiring Harness Fasteners, Battery Tray & Bolts
    GF0031694Courtesy of FORD MOTOR CO.
  70. Install the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  71. Position the air cleaner assembly in place and install the bolt.
    • Tighten to 11 Nm (8 lb-ft).
    72. Fig 66: Locating Air Cleaner Assembly Bracket Bolt
    GF0031639Courtesy of FORD MOTOR CO.
  72. Tighten the air cleaner outlet pipe clamp at the TB.
    • Tighten to 5 Nm (44 lb-in).
    73. Fig 67: Locating Air Cleaner Outlet Pipe Clamp
    GF0031640Courtesy of FORD MOTOR CO.
  73. Connect the engine breather to the air cleaner assembly.
    74. Fig 68: Locating Engine Breather
    GF0031638Courtesy of FORD MOTOR CO.
  74. Connect the brake booster vacuum hose to the air cleaner assembly.
    75. Fig 69: Locating Brake Booster Vacuum Hose
    GF0031637Courtesy of FORD MOTOR CO.
  75. Connect the MAF sensor electrical connector and connect the electrical harness fastener.
    76. Fig 70: Locating Mass Air Flow (MAF) Sensor Electrical Connector & Wiring Harness Fastener
    GF0031636Courtesy of FORD MOTOR CO.
  76. Fill with clean transmission fluid to the correct level.
  77. If a new solenoid body is installed, the solenoid body strategy and solenoid body ID will need to be updated. Refer to Solenoid Body Strategy .
  78. If a replacement transaxle assembly is being installed or a new solenoid body is installed, the PCM will have to be reflashed with a new solenoid body strategy and ID data file. For additional information, refer to Solenoid Body Strategy .
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