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Section 1190 (Manual Transmission): Installation: Transaxle

WARNING: This page is about a different car, the 2008 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
Special Tools

Illustration Tool Name Tool Number
GF0000161Courtesy of FORD MOTOR CO.
 3-Bar Engine Support Kit 303-F072 or equivalent
Material

Item Specification
High Performance DOT 3 Motor Vehicle Brake Fluid
PM-1-C (US); CPM-1-C (Canada)		 WSS-M6C62-A
Premium Long-Life Grease
XG-1-C or XG-1-K (US); CXG-1-C (Canada)		 ESA-M1C75-B
SAE 75W-90 API-GL4 Gear Oil
XY-75W90-QGL		 WSS-M2C203-A1
  1. Do not lubricate the splines on the input shaft.
    2. WARNING: Secure the assembly to the jack. Avoid any obstructions while lowering and raising the jack. Contact with obstructions may cause the assembly to fall off the jack, which may result in serious personal injury.
  2. Raise and position the transaxle to the engine.
  3. Install the 2 short transaxle-to-engine bolts.
    • Tighten to 47 Nm (35 lb-ft).
  4. Install the LH transaxle support insulator bracket.
    • Raise the transaxle, aligning the bracket to the insulator. Install the 3 nuts.
      • Tighten to 40 Nm (30 lb-ft).
  5. Install the rear transaxle support insulator.
    • Install the nuts, the bolt and through bolt. Tighten the through bolt to specification. Do not tighten the nuts and bolt at this time.
      • Tighten to 103 Nm (76 lb-ft).
  6. After removing the transmission jack, install 4 long transaxle-to-engine bolts.
    • Tighten to 47 Nm (35 lb-ft).
  7. Install the front transaxle mount through bolt.
    • Tighten to 115 Nm (85 lb-ft).
  8. Tighten the LH transaxle mount fasteners to specification.
    • Tighten to 40 Nm (30 lb-ft).
  9. Tighten the transaxle rear support insulator fasteners to specification.
    • Install the nuts and bolt.
      • Tighten to 80 Nm (59 lb-ft).
  10. Remove the 3-Bar Engine Support.
  11. Install the RH engine support bolt.
    • Tighten to 90 Nm (66 lb-ft).
  12. Install the 3 upper transaxle-to-engine bolts.
    • Tighten to 45 Nm (33 lb-ft).
    13. Fig 1: 3 Upper Transaxle-To-Engine Bolts
    GF0025340Courtesy of FORD MOTOR CO.
  13. Install the intermediate shaft and the 2 nuts.
    • Tighten to 27 Nm (20 lb-ft).
    14. Fig 2: Locating Intermediate Shaft Retaining Nuts
    GF0024826Courtesy of FORD MOTOR CO.
  14. Install the RH halfshaft onto the intermediate shaft.
    15. Fig 3: Identifying RH Halfshaft
    GF0042137Courtesy of FORD MOTOR CO.
  15. Connect the RH ball joint.
    • Tighten to 63 Nm (46 lb-ft).
  16. Connect the RH stabilizer bar link.
    • Tighten to 55 Nm (41 lb-ft).
  17. Connect the RH tie-rod end.
    • Tighten to 55 Nm (41 lb-ft).
  18. Install the brake hose and the clip.
  19. Position the ABS wire then install the bolt.
  20. Install the LH halfshaft.
  21. Connect the LH ball joint.
    • Tighten to 63 Nm (46 lb-ft).
  22. Connect the stabilizer bar link.
    • Tighten to 55 Nm (41 lb-ft).
  23. Connect the RH tie-rod end.
    • Tighten to 55 Nm (41 lb-ft).
  24. Connect the brake hose and install the clip.
  25. Position the ABS wire then install the bolt.
  26. Install the starter motor assembly. For additional information, refer to STARTING SYSTEM article.
  27. Install the front-to-aft crossmember.
    1. Position the crossmember.
    2. Install the 2 bolts and a nut.
      • Tighten the bolts to 90 Nm (66 lb-ft).
      • Tighten the new nut to 175 Nm (129 lb-ft).
    28. Fig 4: Crossmember & Fasteners
    GF0025425Courtesy of FORD MOTOR CO.
  28. Install the crossmember.
    1. Position the crossmember.
    2. Install the bolts.
      • Tighten to 115 Nm (85 lb-ft).
    29. Fig 5: Crossmember & Bolts
    GF0025426Courtesy of FORD MOTOR CO.
  29. Connect the clutch hydraulic tube.
    1. Position the clutch hydraulic tube.
    2. Connect the clutch hydraulic tube from the clutch slave cylinder.
    3. Install the clutch hydraulic tube bracket-to-transaxle bolt.
      • Tighten to 2.5 Nm (22 lb-in).
    30. Fig 6: Clutch Hydraulic Line & Components
    GF0025430Courtesy of FORD MOTOR CO.
  30. Install the shift cable bracket.
    1. Position the shift cable bracket.
    2. Install the 3 bolts.
      • Tighten to 22 Nm (16 lb-ft).
    31. Fig 7: Shift Cable Bracket & Bolts
    GF0025429Courtesy of FORD MOTOR CO.
  31. Connect the shift cables.
    32. Fig 8: Identifying Shift Cables
    GF0042443Courtesy of FORD MOTOR CO.
  32. Connect the reverse switch and vehicle speed sensor (VSS) connectors.
  33. Install the wiring harness bracket nut.
    • Tighten to 12 Nm (9 lb-ft).
    34. Fig 9: Identifying Nut
    GF0042441Courtesy of FORD MOTOR CO.
  34. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
  35. Install the air cleaner assembly. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - 2.3L article.
    36. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury.
    CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, wash it immediately with cold water.
  36. Fill and bleed the clutch. For additional information, refer to MANUAL TRANSAXLE/TRANSMISSION AND CLUTCH - GENERAL INFORMATION article.
  37. Install the LH side splash shield.
    1. Position the LH splash shield.
    2. Install the 2 screws.
    38. Fig 10: Left Side Splash Shield
    GF0025424Courtesy of FORD MOTOR CO.
  38. Install the wheel and tire assembly. For additional information, refer to WHEELS AND TIRES article.
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