Removal And Installation: Transaxle: Installation

NOTE: Use caution not to damage the engine-to-transaxle separator plate or damage can occur.

Install the new engine-to-transaxle separator plate.

Fig 1: Locating Engine-To-Transaxle Separator Plate
Courtesy of FORD MOTOR CO.
NOTE: If installing the existing transaxle, the halfshaft seals must be replaced or damage to the transaxle can occur.

Using a suitable tool, remove and discard the LH halfshaft seal.

Fig 2: Locating LH Halfshaft Seal
Courtesy of FORD MOTOR CO.
Install the new LH halfshaft seal onto the special tool.

Fig 3: Installing Halfshaft Seal Onto Special Tool
Courtesy of FORD MOTOR CO.
Using the special tools, install the new LH halfshaft seal.

Fig 4: Installing LH Halfshaft Seal Using Special Tools
Courtesy of FORD MOTOR CO.
Using a suitable tool, remove and discard the RH halfshaft seal.

Fig 5: Locating RH Halfshaft Seal
Courtesy of FORD MOTOR CO.
Install the new RH halfshaft seal onto the special tool.

Fig 6: Installing Halfshaft Seal Onto Special Tool
Courtesy of FORD MOTOR CO.
Using the special tools, install the new RH halfshaft seal.

Fig 7: Installing Halfshaft Seal Using Special Tools
Courtesy of FORD MOTOR CO.
If using a new clutch assembly, make sure the clutch-to-flexplate alignment marks are aligned.

Fig 8: Locating Clutch-To-Flexplate Alignment Marks
Courtesy of FORD MOTOR CO.
NOTE: If using the existing clutch assembly, align the index marks on the flexplate and the clutch stud made during removal.

Install the transaxle.

Fig 9: Securing Transaxle Using High-Lift Transmission Jack
Courtesy of FORD MOTOR CO.
Install 2 lower clutch housing-to-engine bolts.
- Tighten to 48 Nm (35 lb-ft).
  
  Fig 10: Locating Lower Clutch Housing-To-Engine Bolts
  Courtesy of FORD MOTOR CO.
NOTE: Rotate the engine in a clockwise direction only or engine damage will occur.

NOTE: Tighten the flexplate-to-clutch nuts in a star pattern or transaxle damage can occur.

NOTE: Using a magnetic socket will help ease the installation of new flexplate-to-clutch nuts. If the flexplate-to-clutch nuts fall into the clutch housing, the transaxle will have to be removed to retrieve them.

Install the 6 new flexplate-to-clutch nuts. Tighten the nuts in a star pattern in 2 stages.
- Stage 1: Tighten nuts 1, 5 and 3 to 12 Nm (106 lb-in).
- Stage 2: Tighten all nuts to 25 Nm (18 lb-ft).
  
  Fig 11: Identifying Flexplate-To-Clutch Nuts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Install the flexplate-to-clutch nut access cover.

Fig 12: Locating Flexplate-To-Clutch Nut Access Cover
Courtesy of FORD MOTOR CO.
Install the starter motor. For additional information, refer to STARTER MOTOR .
If equipped, install the engine splash shield.

Fig 13: Locating Engine Splash Shield Mounting Bolts
Courtesy of FORD MOTOR CO.
Install the 4 lower clutch housing-to-engine bolts.
- Tighten to 48 Nm (35 lb-ft).
  
  Fig 14: Locating Lower Clutch Housing-To-Engine Bolts
  Courtesy of FORD MOTOR CO.
Using the special tools, raise the transaxle.

Fig 15: Supporting Transaxle Using Special Tools
Courtesy of FORD MOTOR CO.
Install the transaxle support insulator and install the 2 transaxle support insulator bolts and the 2 nuts.
- Tighten the 2 bolts to 90 Nm (66 lb-ft).
- Tighten the 2 nuts to 125 Nm (92 lb-ft).
  
  Fig 16: Locating Transaxle Support Insulator, Mounting Bolts And Nuts
  Courtesy of FORD MOTOR CO.
Install the ground wire and bolt onto the transaxle.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 17: Locating Transaxle Ground Wire Bolt
  Courtesy of FORD MOTOR CO.
Install the transaxle roll restrictor and the 2 roll restrictor bolts. Tighten the bolts in the sequence shown in illustration.
1. Tighten to 70 Nm (52 lb-ft).
2. Tighten to 70 Nm (52 lb-ft).
  
  Fig 18: Locating Roll Restrictor And Mounting Bolts
  Courtesy of FORD MOTOR CO.
Attach the HO2S electrical connector to the HO2S bracket.

Fig 19: Locating Heated Oxygen Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Using a new exhaust flange gasket and nuts, connect the exhaust flange to the exhaust.
- Tighten to 48 Nm (35 lb-ft).
  
  Fig 20: Locating Exhaust Flange Nuts
  Courtesy of FORD MOTOR CO.
Using the LH halfshaft seal protector provided with the new LH halfshaft seal, install the LH halfshaft partially into the transaxle.

Fig 21: Installing LH Halfshaft Into Transaxle Using Seal Protector
Courtesy of FORD MOTOR CO.
Remove the LH halfshaft seal protector and install the LH halfshaft into the transaxle.

Fig 22: Installing LH Halfshaft Into Transaxle
Courtesy of FORD MOTOR CO.
Install the LH ball joint into the knuckle.
Install the new LH ball joint bolt and nut.
- Tighten to 48 Nm (35 lb-ft).
  
  Fig 23: Locating LH Ball Joint Bolt And Nut
  Courtesy of FORD MOTOR CO.
Install the brake hose retainer and bolt on the LH strut.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 24: Locating Brake Hose Retainer Bolt
  Courtesy of FORD MOTOR CO.
Using the RH halfshaft seal protector provided with the new RH halfshaft seal, install the RH intermediate shaft assembly partially into the transaxle.

Fig 25: Installing RH Intermediate Shaft Assembly Into Transaxle Using RH Halfshaft Seal Protector
Courtesy of FORD MOTOR CO.
Remove the RH halfshaft seal protector and install the RH intermediate shaft assembly into the transaxle.

Fig 26: Installing RH Intermediate Shaft Assembly Into Transaxle
Courtesy of FORD MOTOR CO.
Install the new bearing retainer strap, shield and bearing retainer strap nuts. Tighten the nuts in 2 stages.
- Stage 1: Tighten to 6 Nm (53 lb-in).
- Stage 2: Tighten to 25 Nm (18 lb-ft).
  
  Fig 27: Identifying Bearing Retainer Strap And Mounting Nuts
  Courtesy of FORD MOTOR CO.
Install the RH ball joint into the knuckle.
Install the new RH ball joint bolt and nut.
- Tighten to 48 Nm (35 lb-ft).
  
  Fig 28: Locating RH Ball Joint Bolt And Nut
  Courtesy of FORD MOTOR CO.
Install the brake hose retainer and bolt on the RH strut.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 29: Locating Brake Hose Retainer Bolt
  Courtesy of FORD MOTOR CO.
Install the front wheels. For additional information, refer to WHEELS & TIRES .
Install the 2 upper clutch housing-to-engine bolts.
- Tighten to 48 Nm (35 lb-ft).
  
  Fig 30: Locating Upper Clutch Housing-To-Engine Bolts
  Courtesy of FORD MOTOR CO.
Connect the engine harness electrical connector to the TCM.

Fig 31: Locating Transmission Control Module
Courtesy of FORD MOTOR CO.
Install the selector lever cable bracket and the 2 selector lever cable bracket bolts on the transaxle.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 32: Locating Selector Lever Cable Bracket Bolts
  Courtesy of FORD MOTOR CO.
Attach the wiring harness to the selector lever cable bracket.

Fig 33: Locating Selector Lever Cable Wiring Harness Clamp
Courtesy of FORD MOTOR CO.
Connect the selector lever cable to the manual control lever.

Fig 34: Locating Manual Control Lever
Courtesy of FORD MOTOR CO.
Attach the transaxle vent hose to the cooling fan housing.

Fig 35: Locating Cooling Fan Housing
Courtesy of FORD MOTOR CO.
Install the battery tray bracket, battery tray bracket nuts and the selector lever cable bracket bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 36: Locating Selector Lever Cable Bracket Bolt And Battery Tray Bracket Nuts
  Courtesy of FORD MOTOR CO.
Attach the wiring harness to the battery tray bracket.

Fig 37: Locating Battery Tray Wiring Harness Clamps
Courtesy of FORD MOTOR CO.
Install the battery tray and the 3 battery tray bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 38: Locating Battery Tray Bolts
  Courtesy of FORD MOTOR CO.
Connect the 3 PCM electrical connectors.

Fig 39: Locating PCM Electrical Connectors
Courtesy of FORD MOTOR CO.
Install the PCM cover and bolt.
- Tighten to 5.4 Nm (47.8 lb-in).
  
  Fig 40: Locating PCM Cover And Mounting Bolt
  Courtesy of FORD MOTOR CO.
Install the ACL assembly and outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION SYSTEM & INTAKE AIR FILTERING SYSTEM .
Install the battery. For additional information, refer to BATTERY AND BATTERY TRAY -- EXPLODED VIEW .
Install the cowl assembly. For additional information, refer to COWL PANEL GRILLE .
Fill the transaxle with transmission fluid. For additional information, refer to TRANSMISSION DRAINING AND FILLING .
Adjust the selector lever cable. For additional information, refer to AUTOMATIC DUAL CLUTCH TRANSAXLE (DCT) POWERSHIFT (DPS6) - EXTERNAL CONTROLS .
Using the scan tool, install all recovered module information after installing the transaxle. For additional information, refer to TRANSMISSION ADAPTIVE LEARNING .