Section 1643 (Automatic Transaxle - 6 Speed): Installation: Transaxle

WARNING: This page is about a different car, the 2006 Mercury Montego and 2006 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.

SPECIAL TOOL(S)

Courtesy of FORD MOTOR CO.	Lifting Bracket Set, Engine (3.0L 4V-V6) 134-00243 or equivalent
Courtesy of FORD MOTOR CO.	Engine Lifting Bracket Set 307-1140
Courtesy of FORD MOTOR CO.	Support Bar, Engine 303-290A
Courtesy of FORD MOTOR CO.	Adapters for 303-290A 303-290A-01
Courtesy of FORD MOTOR CO.	Adapter for 303-290A (Support Leg) 303-290A-03A
Courtesy of FORD MOTOR CO.	Adapter for 303-290A (Lifting Hook) 303-290A-12

MATERIAL SPECIFICATIONS

Item	Specification
Motorcraft Premium Automatic Transmission Fluid XT-8-QW (US); CXT-8-LAW12 (Canada)	WSS-M2C924-A
Multi-Purpose Grease XG-4 and/or XL-5	ESB-M1C93-B
Threadlock and Sealer TA-25	WSK-M2G351-A5

CAUTION:

MERCON®, MERCON®V, MERCON®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.
If a new transaxle or a transmission control module (TCM) is installed, the TCM will need to be reflashed to the latest level calibration available. If the TCM is not reflashed, the wrench light on the dash may illuminate and internal transaxle damage may occur.

NOTE: If the transaxle was overhauled, or if installing a new transaxle and the transmission fluid cooler tubes have not been flushed, flush the fluid cooler tubes at this time. For additional information, refer to TRANSMISSION FLUID COOLER TUBES - BACKFLUSHING AND CLEANING .

If the transaxle was overhauled, or if installing a new transaxle and a new transmission fluid cooler has not been installed, install a new fluid cooler at this time. For additional information, refer to REMOVAL AND INSTALLATION .

If removed, clean the rear transaxle mount bolts using a wire brush and apply new threadlocker to the threads.
If installing a new transaxle, install the rear transaxle mount.
- Tighten to 55 N.m (41 lb-ft).
Fig 1: Locating Rear Transaxle Mount
Courtesy of FORD MOTOR CO.
Prior to installing the transaxle, apply multi-purpose grease to the torque converter pilot hub.

Fig 2: Locating Torque Converter Pilot Hub
Courtesy of FORD MOTOR CO.
Position the transaxle to the back of the engine.
Install the 3 transaxle-to-engine bolts.
- Tighten to 40 N.m (30 lb-ft).
Fig 3: Locating Transaxle-To-Engine Bolts
Courtesy of FORD MOTOR CO.
Using new O-ring seals, connect the transmission fluid cooler tubes to the transaxle.
- Tighten to 10 N.m (89 lb-in).
Fig 4: Locating Transmission Fluid Cooler Tubes Transaxle
Courtesy of FORD MOTOR CO.
Connect the transmission fluid cooler tube bracket.
- Tighten to 10 N.m (89 lb-in).
Fig 5: Locating Transmission Fluid Cooler Tube Bracket
Courtesy of FORD MOTOR CO.
Install 4 new torque converter nuts.
- Tighten to 36 N.m (27 lb-ft).
Fig 6: Locating Torque Converter Nuts
Courtesy of FORD MOTOR CO.
Install the lower rubber access plug and install the retaining pin.

Fig 7: Locating Pushpins & Rubber Access Plug
Courtesy of FORD MOTOR CO.
Position the catalytic converter in place and loosely install the bolt for the bracket.

Fig 8: Locating Bolt For Catalytic Converter Bracket
Courtesy of FORD MOTOR CO.
Connect the heated oxygen sensor (HO2S) electrical connector.

Fig 9: Locating HO2S Electrical Connector
Courtesy of FORD MOTOR CO.
Using a suitable powertrain lift, position the subframe in place and install the 4 bolts.
- Tighten to 90 Nm (66 lb-ft).
Fig 10: Locating Subframe Bolts & Subframe
Courtesy of FORD MOTOR CO.
Install the 2 bolts for the LH rear subframe mount.
- Tighten to 48 N.m (35 lb-ft).
Fig 11: Locating Bolts For LH Rear Subframe Mount
Courtesy of FORD MOTOR CO.
Install the 2 bolts for the RH rear subframe mount.
- Tighten to 48 N.m (35 lb-ft).
Fig 12: Locating Bolts For RH Rear Subframe Mount
Courtesy of FORD MOTOR CO.
Install 2 new bolts for the rear transaxle mount.
- Tighten to 90 N.m (66 lb-ft).
Fig 13: Locating Rear Transaxle Mount
Courtesy of FORD MOTOR CO.
Install the nut for the rear motor mount.
- Tighten to 70 N.m (52 lb-ft).
Fig 14: Locating Nut For Rear Motor Mount
Courtesy of FORD MOTOR CO.
Install the 2 bolts for the lower stabilizer mount.
- Tighten to 70 N.m (52 lb-ft).
Fig 15: Locating Bolts For Lower Stabilizer Mount
Courtesy of FORD MOTOR CO.
Install the nut for the front motor mount.
- Tighten to 70 N.m (52 lb-ft).
Fig 16: Locating Nut For Front Motor Mount
Courtesy of FORD MOTOR CO.
Position the splash shield in place and install the 3 pushpins.

Fig 17: Locating Pushpins & Splash Shield Aside
Courtesy of FORD MOTOR CO.
Connect the HO2S electrical connector to the subframe.

Fig 18: Locating HO2S Electrical Connector From Subframe
Courtesy of FORD MOTOR CO.
Position the power steering rack in place. Install the bolts and nuts.
- Tighten to 133 N.m (98 lb-ft).
Fig 19: Locating Bolts & Nuts For Power Steering Rack
Courtesy of FORD MOTOR CO.
Position the power steering line in place and install the 4 bolts.
- Tighten to 7 N.m (62 lb-in).
Fig 20: Locating Power Steering Line To Subframe
Courtesy of FORD MOTOR CO.
Connect the wire harness to the LH front of the subframe.

Fig 21: Locating Wire Harness From LH Front Of Subframe
Courtesy of FORD MOTOR CO.
Position the lower radiator hose in place and connect the retainers.

Fig 22: Locating Lower Radiator Hose
Courtesy of FORD MOTOR CO.
Install the LH and RH stabilizer bar link into the struts and install new nuts.
- Tighten to 55 Nm (41 lb-ft).
Fig 23: Locating LH & RH Stabilizer Bar Link Nuts
Courtesy of FORD MOTOR CO.
Remove the special tool from the lifting hook near the EGR valve.

Fig 24: Identifying Special Tool (1 Of 4)
Courtesy of FORD MOTOR CO.
Remove the special tools from the RH (rear) cylinder head.

Fig 25: Identifying Special Tool (2 Of 4)
Courtesy of FORD MOTOR CO.
Remove the special tools from the LH (front) cylinder head.

Fig 26: Identifying Special Tool (3 Of 4)
Courtesy of FORD MOTOR CO.
Remove the special tools.

Fig 27: Identifying Special Tool (4 Of 4)
Courtesy of FORD MOTOR CO.
Install new bolts for the catalytic converter.
- Tighten to 40 N.m (30 lb-ft).
Fig 28: Locating New Bolts For Catalytic Converter
Courtesy of FORD MOTOR CO.
Remove the upper half of the lifting hook.

Fig 29: Removing Upper Half Of Lifting Hook
Courtesy of FORD MOTOR CO.
Remove the lower half of the lifting hook.

Fig 30: Removing Lower Half Of Lifting Hook
Courtesy of FORD MOTOR CO.
Install the transaxle-to-engine bolt.
- Tighten to 40 N.m (30 lb-ft).
Fig 31: Locating Transaxle-To-Engine Bolt
Courtesy of FORD MOTOR CO.
Connect the KS wire harness to the transaxle.

Fig 32: Locating KS Wire Harness From Transaxle
Courtesy of FORD MOTOR CO.
Install the KS.
- Tighten to 10 N.m (89 lb-in).
Fig 33: Locating Bolt KS
Courtesy of FORD MOTOR CO.
Install the heat shield over the KS.

Fig 34: Locating Heat Shield For Knock Sensor (KS)
Courtesy of FORD MOTOR CO.
If equipped, connect the engine block heater.

Fig 35: Locating Engine Block Heater Electrical Connector
Courtesy of FORD MOTOR CO.
Position the power steering hose in place and install the bolt.
- Tighten to 7 N.m (62 lb-in).
Fig 36: Locating Bolt For Power Steering Hose
Courtesy of FORD MOTOR CO.
Tighten the catalytic converter bolt to the bracket.
- Tighten to 40 N.m (30 lb-ft).
Fig 37: Locating Bolt For Catalytic Converter Bracket
Courtesy of FORD MOTOR CO.
Install the LH and RH halfshafts. For additional information, refer to INSTALLATION and INSTALLATION .
Position the exhaust crossover pipe and install 2 new bolts for the catalytic converter and connect the rubber hanger.
- Tighten to 40 N.m (30 lb-ft).
Fig 38: Locating Nuts For Catalytic Converter Pipe
Courtesy of FORD MOTOR CO.
Install 2 new nuts for the rear exhaust pipe.
- Tighten to 40 Nm (30 lb-ft).
Fig 39: Locating New Nuts For Rear Exhaust Pipe
Courtesy of FORD MOTOR CO.
Install 2 new nuts for the front exhaust pipe.
- Tighten to 40 N.m (30 lb-ft).
Fig 40: Locating New Nuts For Front Exhaust Pipe
Courtesy of FORD MOTOR CO.
Install the 4 upper transaxle bolts.
- Tighten to 40 Nm (30 lb-ft).
Fig 41: Locating Upper Transaxle Bolts
Courtesy of FORD MOTOR CO.
Install the bolt for the power steering line.
- Tighten to 7 N.m (62 lb-in).
Fig 42: Locating Bolt For Power Steering Hose
Courtesy of FORD MOTOR CO.
Connect the vapor tube to the canister purge valve.

Fig 43: Connecting Vapor Tube To Canister Purge Valve
Courtesy of FORD MOTOR CO.
Install the PCV hose.

Fig 44: Locating Positive Crankcase Ventilation (PCV) Hose
Courtesy of FORD MOTOR CO.
Connect the vacuum hose to the throttle body.

Fig 45: Connecting Vacuum Hoses To Throttle Body
Courtesy of FORD MOTOR CO.
Position the bracket for the power steering hose and install the bolt.
- Tighten to 7 N.m (62 lb-in).
Fig 46: Locating Power Steering Hose & Bolt
Courtesy of FORD MOTOR CO.
Connect the ground wire.
- Tighten to 12 N.m (9 lb-ft).
Fig 47: Connecting Ground Wire
Courtesy of FORD MOTOR CO.
Clean the roll restrictor bolts using a wire brush and apply new threadlock and sealer to the threads.
Position the roll restrictor in place and install the bolts.
- Tighten to 55 N.m (41 lb-ft).
Fig 48: Locating Retaining Bolts
Courtesy of FORD MOTOR CO.
Install the starter motor.
- Tighten to 26 N.m (19 lb-ft).
Fig 49: Locating Bolts For Starter
Courtesy of FORD MOTOR CO.
Connect the 2 starter motor electrical connectors.
- Tighten the larger nut to 12 N.m (9 lb-ft).
- Tighten the smaller nut to 5 N.m (44 lb-in).
Fig 50: Locating Starter Motor Electrical Connectors
Courtesy of FORD MOTOR CO.
Install the electrical cover for the starter motor electrical connectors.

Fig 51: Locating Plastic Electrical Cover For Starter Motor Electrical Connectors
Courtesy of FORD MOTOR CO.
Connect the wire harness to the roll restrictor.

Fig 52: Connecting Wire Harness To Roll Restrictor
Courtesy of FORD MOTOR CO.
Clean the 4 roll restrictor bracket bolts using a wire brush and apply new threadlock and sealer to the threads.
Install the roll restrictor bracket and install 4 new bolts.
- Tighten to 40 Nm (30 lb-ft).
Fig 53: Locating Bolts & Roll Restrictor Bracket
Courtesy of FORD MOTOR CO.
Connect the lower wire harness to the transaxle.

Fig 54: Connecting Lower Wire Harness To Transaxle
Courtesy of FORD MOTOR CO.
Connect the wire harness to the transaxle.

Fig 55: Connecting Wire Harness To Transaxle
Courtesy of FORD MOTOR CO.
Connect the transmission control module (TCM) electrical connector.

Fig 56: Connecting Transmission Control Module (TCM) Electrical Connector
Courtesy of FORD MOTOR CO.
Install the shift cable bracket and bolts.
- Tighten to 25 Nm (18 lb-ft).
Fig 57: Locating Bolts For Shift Cable Bracket
Courtesy of FORD MOTOR CO.
Connect the electrical connector to the shift cable bracket.

Fig 58: Connecting Electrical Connector To Shift Cable Bracket
Courtesy of FORD MOTOR CO.

CAUTION: Be careful not to bend the manual control lever when installing the shift cable.

Fig 59: Locating Shift Cable End

Courtesy of FORD MOTOR CO.

Connect the shift cable end.
Clean the 4 roll restrictor brace bolts using a wire brush and apply new threadlock and sealer to the threads.
Position the roll restrictor brace in place and install the bolts.
- Tighten to 55 Nm (41 lb-ft).
Fig 60: Locating Roll Restrictor Brace Bolts & Brace
Courtesy of FORD MOTOR CO.
Clean the upper roll restrictor bolt using a wire brush and apply new threadlock and sealer to the threads.
Install the upper roll restrictor.
- Tighten to 48 N.m (35 lb-ft).
Fig 61: Locating Upper Roll Restrictor Bolt
Courtesy of FORD MOTOR CO.
Install the cowl panel grille. For additional information, refer to REMOVAL AND INSTALLATION .
Remove the transmission fluid fill plug.

Fig 62: Locating Transmission Fluid Fill Plug
Courtesy of FORD MOTOR CO.
Fill the transaxle with clean automatic transmission fluid.
Install the fluid fill plug.
- Tighten to 39 N.m (29 lb-ft).
Fig 63: Locating Fluid Fill Plug
Courtesy of FORD MOTOR CO.
Install the air cleaner and outlet tube. For additional information, refer to REMOVAL AND INSTALLATION and REMOVAL AND INSTALLATION .
Install the battery tray and the battery. For additional information, refer to REMOVAL AND INSTALLATION .
Remove the fluid level indicator and make sure that the transaxle has fluid in it.
Reflash the TCM to the latest level calibration available.
With the transaxle in (P) PARK, the vehicle should be on a level surface, the engine at idle (680-780 rpm), 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.
Wipe the fluid level indicator cap and remove the fluid level indicator.
Wipe the fluid level indicator with a clean cloth.

NOTE: In order to get an accurate fluid level reading the vehicle should be on a level surface, the engine at idle (680-780 rpm) for 5 minutes and the fluid temperature should be at least 70-80°C (158-176°F) using the scan tool.

Fig 64: Locating Fluid Level Indicator

Courtesy of FORD MOTOR CO.

If fluid needs to be added, add fluid in 0.25 L (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.