Installation

Transaxle - 3.5L

Special Tools:

Material:

CAUTION: MERCON"(R) , MERCON"(R)" V, MERCON "(R)" SP, Motorcraft Premium Automatic Transmission Fluid and Motorcraft Continuously Variable Chain Type Transmission Fluid are not interchangeable transmission fluids. The use of any fluid other than what is recommended for this transmission will cause transmission damage.

NOTE: If the transaxle was overhauled, or if installing a new transaxle and the transmission fluid cooler has not been flushed, flush the fluid cooler at this time. For additional information, refer to Transmission Fluid Cooler - Backflushing and Cleaning.

All vehicles
1. Prior to installing the transaxle, apply multi-purpose grease to the torque converter pilot hub.

2. Position the transaxle to the back of the engine.
3. Install the 7 torque converter housing bolts.
- Tighten to 48 Nm (35 ft. lbs.).

4. Connect the transmission fluid cooler hoses to the transaxle.

5. Install 4 new torque converter nuts.
- Tighten to 36 Nm (27 ft. lbs.).

6. Position the inspection cover in place and install the 2 fasteners.

All wheel drive (AWD) vehicles
7. Position the power transfer unit (PTU) in place and install the 5 bolts.
- Tighten to 90 Nm (66 ft. lbs.).

8. Position the PTU support bracket in place and install the 5 bolts.
- Tighten to 70 Nm (52 ft. lbs.).

9. Position the RH catalytic converter in place and install the 4 nuts.
- Tighten to 40 Nm (30 ft. lbs.).

10. Install the 2 catalytic converter bracket bolts.
- Tighten to 20 Nm (15 ft. lbs.).

11. Connect the RH catalyst monitor electrical connector.

12. Position the driveshaft in place, align the index marks made during removal and install the bolts.
- Tighten to 70 Nm (52 ft. lbs.).

13. Position the RH halfshaft in the transaxle and in the wheel hub and install the 2 bolts.
- Tighten to 23 Nm (17 ft. lbs.).

Front wheel drive (FWD) vehicles
14. Install the RH halfshaft in the transaxle and install the 3 bolts.
- Tighten to 55 Nm (41 ft. lbs.).

15. Install the catalytic converter support bracket and install the 2 nuts.
- Tighten to 23 Nm (17 ft. lbs.).

16. Install the 2 catalytic converter bracket bolts.
- Tighten to 20 Nm (15 ft. lbs.).

All vehicles

17. NOTE: LH shown, RH similar.

Position the subframe in place and install the 2 front subframe nuts.
- Tighten to 150 Nm (111 ft. lbs.).

18. Position the subframe support brackets in place and loosely install the bolts.

19. Install the rear subframe nuts.
- Tighten to 150 Nm (111 ft. lbs.).

20. Tighten the subframe support bracket bolts.
- Tighten to 103 Nm (76 ft. lbs.).

21. Position the steering gear in place and install the 3 bolts.
- Tighten to 107 Nm (79 ft. lbs.).

22. Position the power steering cooler tube in place and install the bolts.
- Tighten to 9 Nm (80 inch lbs.).

23. Install the 2 roll restrictor bracket bolts.
- Tighten to 90 Nm (66 ft. lbs.).

24. Install the bolt connecting the RH damper fork to the lower control arm.
- Tighten to 103 Nm (76 ft. lbs.).

25. Position the lower control arms in the knuckle and install the nuts.
- Tighten to 200 Nm (148 ft. lbs.).

AWD vehicles
26. Using the special tool, install the halfshaft in the wheel hub.

27. Install a new front wheel hub nut.
- Tighten to 255 Nm (185 ft. lbs.).

All vehicles
28. Install the LH halfshaft.

29. NOTE: LH shown, RH similar.

Position the sway bar links in the struts and install the nuts.
- Tighten to 40 Nm (30 ft. lbs.).

30. Position the Y-pipe in place and install the 6 Y-pipe nuts.
- Tighten to 40 Nm (30 ft. lbs.).

31. Install the LH front structure to subframe splash shield and install the pin-type retainers.

32. Position the LH fender splash shield in place and install the 4 screws.

33. Position the RH front structure-to-subframe splash shield in place and install the 6 pin-type retainers.

34. Position the RH fender splash shield in place and install the 4 screws.

35. Apply threadlock to the threads and install the transaxle support insulator bracket, the 2 nuts and the bolt.
- Tighten to 80 Nm (59 ft. lbs.).

36. Using the special tool, raise the transaxle. Apply threadlock to the threads and install the transaxle support insulator through bolt.
- Tighten to 130 Nm (96 ft. lbs.).

37. Remove the special tools.

38. Remove the special tool from the LH cylinder head.

39. Install the 4 upper torque converter housing bolts.
- Tighten to 48 Nm (35 ft. lbs.).

40. Install the starter and the 2 bolts.
- Tighten to 26 Nm (19 ft. lbs.).

41. Connect the 2 starter motor electrical connectors and position back the electrical terminal cover.
- Tighten the larger nut to 12 Nm (9 ft. lbs.).
- Tighten the smaller nut to 5 Nm (44 inch lbs.).

42. Position the 2 ground straps in place and install the 2 ground strap bolts.
- Tighten to 12 Nm (9 ft. lbs.).

43. Connect the wiring harness fasteners on the torque converter housing stud bolt and the starter motor.

44. Connect the transmission control module (TCM) electrical connector.

45. Position the selector lever cable in place and install the 2 bolts and the nut.
- Tighten to 12 Nm (9 ft. lbs.).

46. Connect the shift cable end.

47. Connect the shift cable end.Remove the transmission fluid fill plug.

48. Fill the transaxle with clean automatic transmission fluid.
49. Install the fluid fill plug.
- Tighten to 39 Nm (29 ft. lbs.).

50. Install the upper intake manifold.
51. Install the air cleaner and outlet tube.
52. Install the battery tray and the battery.
53. Remove the fluid level indicator and make sure that the transaxle has fluid in it.
54. With the transaxle in PARK, the vehicle on a level surface, the engine at idle (680-780 rpm) and foot pressed on the brake, move the selector lever through each gear and allow engagement of each gear. Place the selector lever back in the PARK position.
55. Wipe the fluid level indicator cap and remove the fluid level indicator.
56. Wipe the fluid level indicator with a clean cloth.

57. NOTE: In order to get an accurate fluid level reading the vehicle should be on a level surface. Idle the engine to reach the normal operating temperature. Using the scan tool, verify that the transaxle is at normal operating temperature 60°C-70°C (140°F-158°F), prior to adjusting the transmission fluid level.

If fluid needs to be added, add fluid in 0.25L (1/2 pint) increments through the fluid fill plug located on the top of the transaxle near the fluid level indicator. Do not overfill the fluid. Install the fluid level indicator back in the fluid filler tube until it is fully seated, then remove the indicator. The fluid level should be at the upper most mark on the fluid level indicator. Only fill to the upper most mark on the fluid indicator. Do not overfill. Damage to the transaxle will occur.

58. NOTE: The correct transmission fluid level at normal operating temperature of 60°C-70°C (140°F-158°F) is between the top 2 marks on the fluid level indicator.

Fill the transaxle to the correct fluid level.

59. NOTE: The correct transmission fluid level at cold operating temperature of 15°C-25°C (59°F-77°F) is at the bottom mark on the fluid level indicator.

If the transmission fluid temperature is low, fill the fluid to the cold range on the fluid level indicator. Recheck the fluid level when the transaxle has reached the normal operating temperature.