LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Ford >> 2008 >> Fusion S, Standard >> Repair and Diagnosis >> Transmission >> Manual Trans >> Manual Transaxle >> Installation >> Transaxle
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Manual Transaxle: Installation: Transaxle

Special Tools

Illustration Tool Name Tool Number
GF0000161
 Three-Bar Engine Support Kit 303-F072 or equivalent
GF0005600
 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. Secure the transaxle to the transmission jack with a safety strap. Raise and position the transaxle to the engine.
  3. Install the bellhousing-to-oil pan bolt.
    • Tighten to 48 Nm (35 lb-ft).
    4. Fig 1: Locating Bellhousing-To-Oil Pan Bolt
    GF0028776Courtesy of FORD MOTOR CO.
  4. Install the 2 oil pan-to-bellhousing bolts.
    • Tighten to 48 Nm (35 lb-ft).
    5. Fig 2: Locating Oil Pan-To-Bellhousing Bolts
    GF0028777Courtesy of FORD MOTOR CO.
  5. Install the 7 lower transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
  6. Install the 2 transmission lower mount nuts and bolt 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).
    8. Fig 3: Locating Clutch Slave Cylinder Bolts
    GF0028795Courtesy of FORD MOTOR CO.
  8. Install the clutch tube bracket bolts.
    • Tighten to 22 Nm (16 lb-ft).
    9. Fig 4: Locating Clutch Tube Bracket Bolts
    GF0028794Courtesy of FORD MOTOR CO.
  9. Tighten the starter motor bolts to specification.
    • Tighten to 25 Nm (18 lb-ft).
    10. Fig 5: Locating Starter And Stud Bolts
    GF0028784Courtesy of FORD MOTOR CO.
  10. Remove the transmission jack.
    11. Fig 6: Identifying Transmission Jack
    GF0029964Courtesy of FORD MOTOR CO.
    NOTE: Install a new stub shaft circlip.
  11. Install the LH halfshaft into the transaxle. For additional information, refer to FRONT DRIVE HALFSHAFTS article.
    12. NOTE: Install a new stub shaft circlip.
  12. Install the RH intermediate shaft into the transaxle. Install the 2 intermediate shaft support bracket bolts.
    • Tighten to 40 Nm (30 lb-ft).
    13. Fig 7: Locating RH Halfshaft Carrier Bearing Bracket Bolts
    GF0028963Courtesy of FORD MOTOR CO.
  13. Install the roll restrictor mount bracket.
  14. Install the front subframe. For additional information, refer to UNI-BODY, SUBFRAME AND MOUNTING SYSTEM article.
  15. Install the engine roll restrictor bolt.
    • Tighten to 90 Nm (66 lb-ft).
    16. Fig 8: Locating Engine Roll Restrictor Bolt
    GF0028646Courtesy of FORD MOTOR CO.
  16. Connect the reverse lamp switch electrical connector.
  17. Connect the vehicle speed sensor (VSS) electrical connector.
    18. Fig 9: Locating Vehicle Speed Sensor (VSS) Electrical Connector
    GF0028799Courtesy of FORD MOTOR CO.
  18. Tighten the transaxle lower mount nuts and bolt to specification.
    • Tighten to 64 Nm (46 lb-ft).
  19. Install the ground wire and ground wire bolt.
    • Tighten to 10 Nm (89 lb-in).
    20. Fig 10: Locating Ground Wire Bolt
    GF0029963Courtesy of FORD MOTOR CO.
  20. Install the radio frequency interference capacitor, the ground cable and the bolt.
    • Tighten to 10 Nm (89 lb-in).
    21. Fig 11: Locating Radio Frequency Interference Capacitor, Ground Wire And Bolt
    GF0028766Courtesy of FORD MOTOR CO.
  21. Install the 3 upper transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
  22. Attach the wire harness to the transaxle.
  23. Remove the special tool.
    24. Fig 12: Identifying Special Tool (303-F072)
    GF0028746Courtesy of FORD MOTOR CO.
  24. 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.
    25. Fig 13: Locating Control Cables
    GF0028796Courtesy of FORD MOTOR CO.
  25. Install battery tray and the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
  26. Install the air cleaner assembly. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - 2.3L article.
  27. Fill the transaxle with the specified fluid.
  28. Install the splash shield and the 7 bolts, if equipped.
    29. Fig 14: Locating Splash Shield Bolts
    GF0028704Courtesy of FORD MOTOR CO.
  29. Check the vehicle for normal operation.
scientia non olet · About LEMON Manuals