Installation

Transaxle





WARNING: Do not breathe dust or use compressed air to blow dust from storage containers or friction components. Remove dust using government-approved techniques. Friction component dust may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure to follow these instructions may result in serious personal injury.

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.
- Raise the transaxle, aligning the LH transaxle support 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.

6. After removing the transmission jack, install 4 long transaxle-to-engine bolts.
- Tighten to 47 Nm (35 lb-ft).

7. Tighten the LH transaxle support insulator through bolt to specification.
- Tighten to 103 Nm (76 lb-ft).

8. Tighten the transaxle rear support insulator fasteners to specification.
- Install the nuts and bolt.
- Tighten to 80 Nm (59 lb-ft).

9. Remove the Engine Support Bar that was installed during the removal procedure.

10. Install the RH engine support bolt.
- Tighten to 90 Nm (66 lb-ft).

11. Install the 3 upper transaxle-to-engine bolts.
- Tighten to 47 Nm (35 lb-ft).





12. Install the intermediate shaft, heat shield and the 2 nuts.
- Tighten to 27 Nm (20 lb-ft).





13. Install the RH halfshaft onto the intermediate shaft.





14. Connect the RH ball joint.
- Tighten to 63 Nm (46 lb-ft).

15. Connect the RH stabilizer bar link.
- Tighten to 55 Nm (41 lb-ft).

16. Connect the RH tie-rod end.
- Tighten to 55 Nm (41 lb-ft).

17. Install the brake hose and the clip.

18. Position the ABS wire then install the bolt.

19. Install the LH halfshaft.

20. Connect the LH ball joint.
- Tighten to 63 Nm (46 lb-ft).

21. Connect the stabilizer bar link.
- Tighten to 55 Nm (41 lb-ft).

22. Connect the RH tie-rod end.
- Tighten to 55 Nm (41 lb-ft).

23. Connect the brake hose and install the clip.

24. Position the ABS wire then install the bolt.

25. Install the starter motor assembly. For additional information, refer to Starting System Service and Repair.

26. 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).





27. Install the transaxle front support insulator through bolt.
- Tighten to 115 Nm (85 lb-ft).

28. Install the crossmember.

1. Position the crossmember.

2. Install the bolts.
- Tighten to 115 Nm (85 lb-ft).





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. Install the shift cable bracket.

1. Position the shift cable bracket.

2. Install the 3 bolts.
- Tighten to 22 Nm (16 lb-ft).





31. Connect the shift cables.





32. Connect the reverse switch and Vehicle Speed Sensor (VSS) connectors.

33. Install the wiring harness bracket nut.
- Tighten to 12 Nm (106 lb-in).





34. Install the battery tray. For additional information, refer to Battery, Mounting and Cables Battery Tray.

35. Install the Air Cleaner (ACL) assembly. For additional information, refer to Intake Air Distribution and Filtering - 2.5L Air Cleaner.

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.

NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.

Fill and bleed the clutch. For additional information, refer to Manual Transaxle/Transmission and Clutch - General Information Service and Repair.

37. Install the LH side splash shield.

1. Position the LH splash shield.

2. Install the 2 screws.





38. Install the wheel and tire. For additional information, refer to Wheels and Tires Removal and Replacement.