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Automatic Transmission: Installation: Transaxle: Installation

All vehicles 

NOTE: Prior to installation of a new, re-manufactured or overhauled transaxle, the transmission fluid cooler tubes must be cleaned, otherwise transaxle failure may occur.
NOTE: Prior to installation of a new, re-manufactured or overhauled transaxle, flush out the cooler and cooler tubes. 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 new backing rings or seals if necessary. Lubricate the transmission fluid cooler tube seals with clean transmission fluid and install the backing rings and seals on the transmission fluid cooler tubes.
    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 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 new transmission fluid cooler tube bolts.
    • Tighten to 9 Nm (80 lb-in).
    4. Fig 3: Transmission Fluid Cooler Tube Bolts
    GF0043916Courtesy of FORD MOTOR CO.
    NOTE: Make sure that when installing the manual control lever, it is fully seated onto the manual control lever shaft. Damage to the manual control lever shaft will occur and the lever will come loose.
    NOTE: Make sure to hold the manual control lever while tightening the manual control lever nut or damage to the manual control lever and park components will occur.
  4. Install the manual control lever and the nut.
    • Tighten to 18 Nm (159 lb-in).
    5. Fig 4: Manual Control Lever
    GF0043915Courtesy of FORD MOTOR CO.
  5. Lubricate the torque converter pilot hub with grease.
    6. NOTE: If the transaxle is not positioned on the dowel pins, damage to the transaxle may occur.
  6. If the dowel pins were pulled out of the engine block during removal, install new dowel pins in the engine block.
    7. Fig 5: Locating Dowel Pin From Torque Converter Housing
    GF0031715Courtesy of FORD MOTOR CO.
  7. Using the Transmission Jack Adapter, support the transaxle.
    8. Fig 6: Supporting Transaxle Using Special Tool (209-00152) & A Suitable Transmission Jack
    GF0031713Courtesy of FORD MOTOR CO.
  8. Position the transaxle in place and install the lower torque converter housing bolts.
    • Tighten to 48 Nm (35 lb-ft).
    9. Fig 7: Locating Torque Converter Housing Bolts
    GF0031714Courtesy of FORD MOTOR CO.
  9. Install the transaxle support insulator bracket, the nuts and the bolt.
    • Tighten to 63 Nm (46 lb-ft).
    10. Fig 8: Identifying Bolt, Nuts And Mount Bracket
    GF0045673Courtesy of FORD MOTOR CO.
  10. Raise the transaxle and install the transaxle support insulator through bolt.
    • Tighten to 175 Nm (129 lb-ft).
    11. Fig 9: Identifying Transaxle Support Insulator Bolt
    GF0031405Courtesy of FORD MOTOR CO.
  11. Install the transmission fluid cooler tubes in the transmission fluid cooler thermal bypass valve.
    12. Fig 10: Locating Transmission Fluid Cooler Tubes
    GF0031423Courtesy of FORD MOTOR CO.
  12. Install the secondary latches on the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.
    13. Fig 11: Locating Secondary Latches On Transmission Fluid Cooler Tubes
    GF0031391Courtesy of FORD MOTOR CO.
  13. Install 3 new torque converter bolts.
    • Tighten to 55 Nm (41 lb-ft).
    14. Fig 12: Locating Torque Converter Bolts
    GF0031394Courtesy of FORD MOTOR CO.
  14. Install the inspection cover and the 2 fasteners.
    15. Fig 13: Locating Oil Fasteners On Inspection Cover
    GF0031393Courtesy of FORD MOTOR CO.

    All-Wheel Drive (AWD) vehicles 

  15. Position the Power Transfer Unit (PTU) in place and install the bolts.
    • Tighten to 90 Nm (66 lb-ft).
    16. Fig 14: Identifying PTU & Bolts
    GF0031403Courtesy of FORD MOTOR CO.
  16. If necessary, install a new cover seal. Using the Halfshaft Oil Seal Installer and the PTO Drive Gear Outer Oil Seal Installer, seat the new cover seal.
    17. Fig 15: Seating Cover Seal Using Special Tools (308-431) & (308-430)
    GF0030128Courtesy of FORD MOTOR CO.
  17. Using the PTU Linkshaft Seal Installer and Handle, install a new intermediate shaft seal.
    18. Fig 16: Identifying Special Tool
    GF0045837Courtesy of FORD MOTOR CO.
    NOTE: Do not overheat (melt) the seal deflector. Overheating will damage the deflector. If the deflector is damaged, a new one must be used.
  18. Using a 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. An audible snap should be heard.
    • If necessary, use the PTU Linkshaft Seal Dust Shield Installer and Handle to seat the seal deflector. Make sure the deflector is fully seated and there are no cracks on the face or inner diameter white-colored tab.
    • An alternate method to heat the seal deflector, place the deflector in boiling water for 3 to 5 minutes. Dry the deflector and install.
    • Make sure the deflector is completely seated all the way around. It is correctly installed when the face of the deflector is recessed into the pocket.
    19. Fig 17: Identifying Special Tools
    GF0045838Courtesy of FORD MOTOR CO.
  19. Position the PTU support bracket in place and install the bolts.
    • Tighten to 70 Nm (52 lb-ft).
    20. Fig 18: Locating Power Transfer Unit (PTU) Support Bracket & Bolts
    GF0029153Courtesy of FORD MOTOR CO.
  20. Position the RH catalytic converter in place and loosely install the 4 nuts.
    21. Fig 19: Identifying Nuts
    GF0045835Courtesy of FORD MOTOR CO.
  21. Install the RH catalytic converter support bracket bolts.
    • Tighten to 20 Nm (177 lb-in).
    22. Fig 20: Identifying Bolts
    GF0045834Courtesy of FORD MOTOR CO.
  22. Tighten the 4 RH catalytic converter nuts.
    • Tighten to 40 Nm (30 lb-ft).
    23. Fig 21: Identifying Nuts
    GF0045835Courtesy of FORD MOTOR CO.
  23. Connect the RH catalyst monitor electrical connector.
    24. Fig 22: Identifying RH Catalyst Monitor Electrical Connector
    GF0031711Courtesy of FORD MOTOR CO.
  24. Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal and install new driveshaft bolts.
    • Tighten to 70 Nm (52 lb-ft).
    25. Fig 23: Identifying Bolts
    GF0045833Courtesy of FORD MOTOR CO.

    All vehicles 

    NOTE: RH shown in illustration, LH similar.
  25. Loosely install the RH and LH front subframe bolts.
    26. Fig 24: Identifying Bolt
    GF0045665Courtesy of FORD MOTOR CO.
    NOTE: RH shown in illustration, LH similar.
  26. Position the RH and LH subframe support brackets in place and loosely install the bracket bolts.
    27. Fig 25: Identifying Bracket And Bolts
    GF0045689Courtesy of FORD MOTOR CO.
    NOTE: RH shown in illustration, LH similar.
  27. Loosely install the RH and LH rear subframe bolts.
    28. Fig 26: Identifying Bolt
    GF0045839Courtesy of FORD MOTOR CO.
    NOTE: RH shown in illustration, LH similar.
  28. Tighten the RH and LH front subframe bolts.
    • Tighten to 150 Nm (111 lb-ft).
    29. Fig 27: Identifying Bolt
    GF0045665Courtesy of FORD MOTOR CO.
    NOTE: RH shown in illustration, LH similar.
  29. Tighten the RH and LH rear subframe bolts.
    • Tighten to 150 Nm (111 lb-ft).
    30. Fig 28: Identifying Bolt
    GF0045839Courtesy of FORD MOTOR CO.
    NOTE: RH shown in illustration, LH similar.
  30. Tighten the RH and LH subframe support bracket bolts.
    • Tighten to 55 Nm (41 lb-ft).
    31. Fig 29: Identifying Bracket-To-Body Bolts
    GF0045663Courtesy of FORD MOTOR CO.
  31. Position the roll restrictor in place and install the bolts.
    • Tighten to 90 Nm (66 lb-ft).
    32. Fig 30: Identifying Bolts
    GF0045659Courtesy of FORD MOTOR CO.
  32. Position the stabilizer bar in place and install new bolts.
    • Tighten to 48 Nm (35 lb-ft).
    33. Fig 31: Locating Stabilizer Bar & Bolts
    GF0031308Courtesy of FORD MOTOR CO.
  33. Position the power steering rack in place and install new bolts and nuts.
    • Tighten to 117 Nm (86 lb-ft).
    34. Fig 32: Locating Bolts & Nuts For Power Steering Rack
    G03990956Courtesy of FORD MOTOR CO.
  34. Position the exhaust Y-pipe assembly in place and install the new nuts.
    • Tighten to 40 Nm (30 lb-ft).
    35. Fig 33: Locating Exhaust Flexible Pipe, Y-Pipe & Nuts
    GF0031306Courtesy of FORD MOTOR CO.
  35. Install the exhaust hanger and the exhaust flange nuts.
    • Tighten to 40 Nm (30 lb-ft).
    36. Fig 34: Identifying Nuts And Exhaust Hanger
    GF0045832Courtesy of FORD MOTOR CO.
  36. Position the LH halfshaft in the transaxle and in the steering knuckle.
  37. Install the RH halfshaft and install the RH halfshaft bearing support bracket nuts.
    • Tighten to 40 Nm (30 lb-ft).
    38. Fig 35: Identifying Nuts
    GF0045667Courtesy of FORD MOTOR CO.
    NOTE: RH side shown in illustration, LH side similar.
  38. Join the lower control arms to the knuckles then install new RH and LH ball joint nuts.
    • Tighten to 115 Nm (85 lb-ft).
    39. Fig 36: Identifying Nut And Wheel Knuckles
    GF0045662Courtesy of FORD MOTOR CO.
    NOTE: Install and tighten the new front axle wheel end nut to specification in a continuous rotation. Stopping the rotation during installation will cause the nylon lock to seat incorrectly. This will cause incorrect torque readings while tightening the front axle wheel end nut and lead to bearing failure. Always install a new front axle wheel end nut after loosening or when not tightened to specifications in a continuous rotation.
    NOTE: Never use power tools to tighten the front axle wheel end nut or damage to the nut or wheel bearing may occur.
    NOTE: RH side shown in illustration, LH side similar.
    NOTE: Apply the brake to keep the halfshaft from rotating.
  39. Install new RH and LH halfshaft nuts.
    • Tighten to 350 Nm (258 lb-ft).
    40. Fig 37: Locating RH Front Halfshaft Nut
    GF0031348Courtesy of FORD MOTOR CO.
  40. Position the power steering tube in place on the LH side of the subframe and install the 3 power steering tube bracket bolts.
    • Tighten to 9 Nm (80 lb-in).
    41. Fig 38: Power Steering Tube Bracket Bolt
    GF0043914Courtesy of FORD MOTOR CO.
  41. Install the front splash shield, the screws and the pushpin fasteners.
    42. Fig 39: Identifying Pushpin Fasteners
    GF0045831Courtesy of FORD MOTOR CO.
  42. Install the RH splash shield and the pushpin fasteners.
    43. Fig 40: Identifying Pushpin Fasteners
    GF0045830Courtesy of FORD MOTOR CO.
  43. Remove the Engine Support Bar and Engine Spreader Bar.
    44. Fig 41: Engine Support Bar & Engine Spreader Bar
    GF0043913Courtesy of FORD MOTOR CO.
  44. Remove the Engine Lift Eye from the LH cylinder head.
    45. Fig 42: Special Tool (303-1245) On LH Cylinder Head
    GF0029677Courtesy of FORD MOTOR CO.
  45. Install the top torque converter housing bolts.
    • Tighten to 48 Nm (35 lb-ft).
    46. Fig 43: Identifying Bolts
    GF0045829Courtesy of FORD MOTOR CO.
    NOTE: Coolant hoses removed for clarity.
  46. Install the transmission fluid filler tube and the nut.
    • Tighten to 11 Nm (97 lb-in).
    47. Fig 44: Identifying Transmission Fluid Filler Tube
    GF0031643Courtesy of FORD MOTOR CO.
    NOTE: Coolant hoses removed for clarity.
  47. Install the transmission fluid level indicator.
    48. Fig 45: Identifying Transmission Fluid Level Indicator
    GF0031642Courtesy of FORD MOTOR CO.
  48. Route the coolant hoses to the correct position on the transmission fluid filler tube.
    49. Fig 46: Identifying Coolant Hoses From Transmission Fluid Filler Tube
    GF0031641Courtesy of FORD MOTOR CO.
  49. Connect the transaxle electrical connector and install the wiring harness fastener on the main control cover stud.
    50. Fig 47: Identifying Connector And Wiring Harness Fastener
    GF0045812Courtesy of FORD MOTOR CO.
  50. If equipped, position the auxiliary coolant pump on the transaxle studs and install the 2 nuts.
    • Tighten to 20 Nm (177 lb-in).
    51. Fig 48: Identifying Auxiliary Coolant Pump
    GF0045828Courtesy of FORD MOTOR CO.
  51. Install the starter, the bolt and studbolt.
    • Tighten to 26 Nm (19 lb-ft).
    52. Fig 49: Identifying Bolt, Stud Bolt & Starter
    GF0031409Courtesy of FORD MOTOR CO.
  52. Install the wiring harness fastener on the starter motor studbolt.
    53. Fig 50: Identifying Wiring Harness Retainer From Starter Motor Stud Bolt
    GF0031408Courtesy of FORD MOTOR CO.
  53. Connect the starter motor terminals and position the starter terminal boot over the battery cable terminal.
    1. Tighten the starter battery terminal nut to 12 Nm (106 lb-in).
    2. Tighten the starter solenoid terminal nut to 6 Nm (53 lb-in).
    54. Fig 51: Identifying Starter Motor Wire Terminals & Nuts
    GF0029337Courtesy of FORD MOTOR CO.
  54. Install the starter motor positive terminal cover.
    55. Fig 52: Identifying Starter Motor Solenoid Cover
    GF0045674Courtesy of FORD MOTOR CO.
  55. Position the selector lever cable and bracket in place and install the bolts.
    • Tighten to 12 Nm (106 lb-in).
    56. Fig 53: Identifying Bolts
    GF0045827Courtesy of FORD MOTOR CO.
  56. Place the selector lever in DRIVE.
    57. Fig 54: Placing Selector Lever In Drive
    GF0031990Courtesy of FORD MOTOR CO.
  57. 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.
    58. Fig 55: Rotating Manual Control Lever Clockwise & Counterclockwise
    GF0031966Courtesy of FORD MOTOR CO.
  58. Unlock the selector lever cable adjuster by sliding the locking tab over.
    59. Fig 56: Unlocking Adjuster By Sliding Locking Tab Over
    GF0031991Courtesy of FORD MOTOR CO.
  59. Slide the cable end forward or backward to align it with the manual lever.
    60. Fig 57: Sliding Cable End Forward Or Backward To Align It With Manual Lever
    GF0031992Courtesy of FORD MOTOR CO.
  60. With the adjuster locking tab released, connect the selector lever cable end to the manual control lever.
    61. Fig 58: Connecting Selector Lever Cable End To Manual Lever
    GF0031969Courtesy of FORD MOTOR CO.
  61. Slide the release tab back to lock the adjuster.
    62. Fig 59: Sliding Release Tab Back To Lock Adjuster
    GF0031970Courtesy of FORD MOTOR CO.
  62. Install the upper intake manifold. For additional information, refer to ENGINE - 3.5L article.
  63. Install the battery tray and bracket, install the battery tray bolt and the nut.
    • Tighten to 9 Nm (80 lb-in).
    64. Fig 60: Identifying Bolt, Nut And Bracket
    GF0045646Courtesy of FORD MOTOR CO.
  64. Install the lower battery tray bracket bolts.
    • Tighten to 9 Nm (80 lb-in).
    65. Fig 61: Identifying Bolts
    GF0045645Courtesy of FORD MOTOR CO.
  65. Attach the pin-type wiring harness fasteners to the battery tray.
    66. Fig 62: Identifying Retainers
    GF0045818Courtesy of FORD MOTOR CO.
  66. Install the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
  67. Position the Air Cleaner (ACL) assembly in place and install the ACL assembly bracket bolts.
    • Tighten to 11 Nm (97 lb-in).
    68. Fig 63: Identifying Bolts
    GF0045824Courtesy of FORD MOTOR CO.
  68. Connect the brake booster vacuum hose to the ACL outlet pipe.
    69. Fig 64: Identifying ACL Outlet Pipe
    GF0045825Courtesy of FORD MOTOR CO.
  69. Tighten the ACL outlet pipe clamp at the Throttle Body (TB).
    • Tighten to 5 Nm (44 lb-in).
    70. Fig 65: Identifying ACL Outlet Pipe Clamp
    GF0045826Courtesy of FORD MOTOR CO.
  70. Connect the engine breather to the ACL assembly.
    71. Fig 66: Locating Engine Breather
    GF0031638Courtesy of FORD MOTOR CO.
  71. Connect the Mass Air Flow (MAF) sensor electrical connector.
    72. Fig 67: Identifying MAF Sensor Connector
    GF0045810Courtesy of FORD MOTOR CO.
  72. Install the front wheels. For additional information, refer to WHEELS AND TIRES article.
  73. Fill with clean transmission fluid to the correct level.
  74. If a new solenoid body is installed, the solenoid body strategy will need to be updated. Refer to Solenoid Body Strategy .
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