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Transaxle - 2.3L: Installation

WARNING: This page is about a different car, the 2004 Ford Focus. However, it is still accessible from the selected car via links, so may be relevant.
  1. Make sure that the torque converter is installed correctly.
    2. NOTE: Lubricate the torque converter pilot hub with multi-purpose grease.
    Fig 1: Checking Installation Depth Of Torque Converter
    G03192700Courtesy of FORD MOTOR CO.
  2. Check the installation depth of the torque converter.
    1. Lay a steel straightedge on the automatic transaxle flange.
    2. Check the installation depth between the transaxle flange and the torque converter centering spigot for the correct clearance.
  3. Remove the special tool.
    Fig 2: Removing Special Tool
    G03192701Courtesy of FORD MOTOR CO.
  4. Using a high-lift jack, secure the transaxle using a safety strap.
    5. NOTE: Make sure that the dowel pins are installed in the engine block prior to installing the transaxle.
  5. Move the transaxle into position.
    6. NOTE: The location of the different length bolts.
    Fig 3: Installing LH Converter Housing Bolts
    G03192702Courtesy of FORD MOTOR CO.
  6. Install the three LH converter housing bolts.
  7. Install the three RH converter housing bolts.
    Fig 4: Installing RH Converter Housing Bolts
    G03192703Courtesy of FORD MOTOR CO.
    8. CAUTION: Only rotate the engine in a clockwise direction or engine damage will occur.
    NOTE: Only install new self-locking nuts.
    Fig 5: Installing Torque Converter To Flexplate
    G03192704Courtesy of FORD MOTOR CO.
  8. Using the four nuts, install the torque converter to the flexplate.
  9. Remove the safety strap from the transaxle.
  10. Install the fluid filler tube.
    Fig 6: Installing Fluid Filler Tube
    G03192705Courtesy of FORD MOTOR CO.
  11. Install the engine rear mount bracket.
    Fig 7: Installing Engine Rear Mount Bracket
    G03192706Courtesy of FORD MOTOR CO.
  12. Install the engine rear mount.
    Fig 8: Installing Engine Rear Mount
    G03192707Courtesy of FORD MOTOR CO.
  13. Install the fluid cooler tubes.
    Fig 9: Installing Fluid Cooler Tubes
    G03192708Courtesy of FORD MOTOR CO.
  14. Connect the output speed (OSS) sensor electrical connector.
    Fig 10: Connecting OSS Sensor Electrical Connector
    G03192709Courtesy of FORD MOTOR CO.
    15. NOTE: Install a new snap ring.
    Fig 11: Installing LH Front Drive Halfshaft
    G03192710Courtesy of FORD MOTOR CO.
  15. Install the LH front drive halfshaft.
    16. NOTE: Install new nuts and a new center bearing cap.
    Fig 12: Installing RH Front Halfshaft Together With Intermediate Shaft
    G03192711Courtesy of FORD MOTOR CO.
  16. Install the RH front halfshaft together with the intermediate shaft.
  17. Install the mounting bracket for the front drive halfshaft intermediate bearing.
    Fig 13: Installing Mounting Bracket For Front Drive Halfshaft Intermediate Bearing
    G03192712Courtesy of FORD MOTOR CO.
  18. Install both of the lower control arms to the knuckles.
    1. Connect the suspension arm ball joint.
    2. Install the bolt.
    Fig 14: Connecting Suspension Arm Ball Joint
    G03192713Courtesy of FORD MOTOR CO.
  19. Install both of the tie-rod ends to the knuckles.
    Fig 15: Installing Tie-Rod Ends To Knuckles
    G03192714Courtesy of FORD MOTOR CO.
  20. Connect the stabilizer bar at the strut.
    Fig 16: Connecting Stabilizer Bar At Strut
    G03192715Courtesy of FORD MOTOR CO.
  21. Install the engine RH support insulator.
    Fig 17: Installing Engine RH Support Insulator
    G03192716Courtesy of FORD MOTOR CO.
  22. Install the starter isolator.
    Fig 18: Installing Starter Isolator
    G03192717Courtesy of FORD MOTOR CO.
  23. Install the starter motor and insert the three bolts.
    Fig 19: Installing Starter Motor
    G03192718Courtesy of FORD MOTOR CO.
  24. Connect the starter motor electrical connectors.
    Fig 20: Connecting Starter Motor Electrical Connectors
    G03192719Courtesy of FORD MOTOR CO.
  25. Connect the bracket to the starter stud.
    Fig 21: Connecting Bracket To Starter Stud
    G03192720Courtesy of FORD MOTOR CO.
  26. Install the fluid filler tube and shift cable bracket bolts.
    Fig 22: Installing Fluid Filler Tube And Shift Cable Bracket Bolts
    G03192721Courtesy of FORD MOTOR CO.
    27. NOTE: The location of the different length bolts.
    Fig 23: Installing Upper Center Converter Housing Bolts
    G03192722Courtesy of FORD MOTOR CO.
  27. Install the upper center converter housing bolts.
  28. Install the shift cable into the clip.
    Fig 24: Installing Shift Cable Into Clip
    G03192723Courtesy of FORD MOTOR CO.
  29. Connect the turbine shaft speed (TSS) sensor electrical connector.
    Fig 25: Connecting TSS Sensor Electrical Connector
    G03192724Courtesy of FORD MOTOR CO.
  30. Connect the electrical connectors and install the selector lever cable to the automatic transaxle selector lever.
    1. Transmission range (TR) sensor.
    2. Transaxle solenoid electrical connector.
    Fig 26: Installing Selector Lever Cable To Automatic Transaxle Selector Lever
    G03192725Courtesy of FORD MOTOR CO.
  31. Using the engine support bar, raise the engine and transaxle assembly slightly.
  32. Tighten the LH strut and spring assembly top mount nuts.
    Fig 27: Tightening LH Strut And Spring Assembly Top Mount Nuts
    G03192726Courtesy of FORD MOTOR CO.
  33. Install the air cleaner resonator.
    1. Install the resonator and nuts.
    2. Connect the air cleaner outlet hose.
    3. Connect the crankcase ventilation hose.
    Fig 28: Installing Air Cleaner Resonator
    G03192727Courtesy of FORD MOTOR CO.
    34. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven to relearn the strategy.
    Fig 29: Installing Battery Tray
    G03192728Courtesy of FORD MOTOR CO.
  34. Install the battery tray and battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  35. Fill the transaxle with clean automatic transmission
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