Installation
TransaxleSpecial Tool(s):
Material:
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.
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.
1 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. If equipped, install the power transfer unit (PTU).
8. Install the intermediate shaft.
9. Install the RH halfshaft.
10. Connect the RH ball joint.
^ Tighten to 63 Nm (46 lb-ft).
11. Connect the RH stabilizer bar link.
^ Tighten to 55 Nm (41 lb-ft).
12. Connect the RH tie-rod end.
^ Tighten to 55 Nm (41 lb-ft).
13. Install the brake hose and the clip.
14. Position the ABS wire then install the bolt.
15. Install the LH halfshaft.
16. Connect the LH ball joint.
^ Tighten to 63 Nm (46 lb-ft).
17. Connect the stabilizer bar link.
^ Tighten to 55 Nm (41 lb-ft).
18. Connect the RH tie-rod end.
^ Tighten to 55 Nm (41 lb-ft).
19. Connect the brake hose and install the clip
20. Position the ABS wire then install the bolt.
21. Install the starter motor assembly. For additional information, refer to Starting System.
22. 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).
23. Install the crossmember.
1 Position the crossmember.
2 Install the bolts.
^ Tighten to 115 Nm (85 lb-ft).
24. Install the front transaxle mount through bolt.
^ Tighten to 115 Nm (85 lb-ft).
25. Tighten the LH transaxle mount fasteners to specification.
^ Tighten to 40 Nm (30 lb-ft).
26. Tighten the transaxle rear support insulator fasteners to specification.
^ Install the nuts and bolt.
- Tighten to 80 Nm (59 lb-ft).
27. Remove the 3-Bar Engine Support.
28. Install the RH engine support bolt.
^ Tighten to 90 Nm (66 lb-ft).
29. Install the 3 upper transaxle-to-engine bolts.
^ Tighten the bolts to 45 Nm (33 lb-ft).
30. 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).
31. Install the shift cable bracket.
1 Position the shift cable bracket.
2 Install the 3 bolts.
^ Tighten to 22 Nm (16 lb-ft).
32. Connect the shift cables.
33. Connect the reverse switch and vehicle speed sensor (VSS) connectors.
34. Install the wiring harness bracket nut.
^ Tighten to 12 Nm (9 lb-ft).
35. Install the battery tray.
36. Install the air cleaner assembly. For additional information, refer to Fuel Delivery and Air Induction.
37. Fill the transaxle fluid. For additional information, refer to Transaxle Draining and Filling.
38. 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. 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.
Fill and bleed the clutch.
39. Install the LH side splash shield.
1 Position the LH splash shield.
2 Install the 2 screws.
40. Install the RH side splash shield.
41. Install the wheel and tire assembly.