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Removal And Installation: Transaxle: Installation

NOTE: Prior to installing a new, re-manufactured or overhauled transmission, clean the transmission fluid cooler tubes. Failure to clean the transmission fluid cooler tubes can result in transmission failure.
NOTE: If the transmission was overhauled, or if installing a new transmission and the transmission fluid cooler has not been flushed, flush the transmission fluid cooler at this time. Refer to TRANSMISSION FLUID COOLER BACKFLUSHING AND CLEANING . Clean the transmission-mounted transmission fluid cooler tubes by hand.
  1. Lubricate the torque converter pilot hub with Multi-Purpose Grease.
    Fig 1: Identifying Torque Converter Pilot Hub
    G07932117Courtesy of FORD MOTOR CO.
    2. NOTE: If the transmission is not positioned on the dowel pins, damage to the transmission may occur.
    Fig 2: Locating Dowel Pins
    G07932118Courtesy of FORD MOTOR CO.
  2. If the dowel pins were pulled out of the engine block during removal, install new dowel pins in the engine block.
  3. Support the transmission with a transmission jack. Secure the transmission to the transmission jack with a safety strap.
  4. Position the transmission behind the engine and remove the Torque Converter Retainer.
    Fig 3: Identifying Torque Converter Retainer
    G07932116Courtesy of FORD MOTOR CO.
  5. Align the torque converter stud marked during removal with the flexplate, position the transmission on the dowel pins and install the 8 lower transmission-to-engine bolts.
    • Nm (35 lb-ft).
      Fig 4: Locating Lower Transmission-To-Engine Bolts
      G07932115Courtesy of FORD MOTOR CO.
  6. Apply Threadlock and Sealer to the threads and install the transmission support insulator bracket, 3 transmission support insulator bracket nuts, transmission support insulator bracket bolt and the wiring retainer.
    1. Tighten to 80 Nm (59 lb-ft).
    2. Tighten to 63 Nm (46 lb-ft).
      Fig 5: Locating Transmission Support Insulator Fasteners And Wiring Retainer
      G07932058Courtesy of FORD MOTOR CO.
  7. Align the transmission support insulator bracket with the transmission support insulator, apply Threadlock and Sealant to the threads and install the transmission support insulator through bolt.
    • Tighten to 175 Nm (130 lb-ft).
      Fig 6: Locating Transaxle Support Insulator Through Bolt And Nut
      G07928297Courtesy of FORD MOTOR CO.
  8. Remove the Engine Support Bar.
    Fig 7: Identifying Engine Support Bar
    G07932053Courtesy of FORD MOTOR CO.
  9. Install the cowl panel grille. Refer to FRONT END BODY PANELS .
  10. Connect the TSS sensor electrical connector, connect the transmission electrical connector and install the 2 wiring retainers on the main control cover studs.
    Fig 8: Locating Transmission Electrical Connector, Wiring Retainers And Main Control Cover Studs
    G07932111Courtesy of FORD MOTOR CO.
  11. Install the catalytic converter. Refer to EXHAUST SYSTEM .
  12. Position the transmission fluid cooler tubes in place and install the 2 transmission fluid cooler tube bolts.
    • Tighten to 9 Nm (80 lb-in).
      Fig 9: Locating Transmission Fluid Cooler Tube Bracket Bolts
      G07932110Courtesy of FORD MOTOR CO.
    13. NOTE: Make sure to install the correct circlip for this application. Failure to use the correct diameter circlip may result in shaft removal concerns or shaft damage during vehicle operation.
    Fig 10: Locating Circlip
    G07928641Courtesy of FORD MOTOR CO.
  13. Install a new circlip.
  14. Install the Differential Oil Seal Protector on the LH halfshaft seal.
    Fig 11: Identifying Differential Oil Seal Protector On LH Halfshaft Seal
    G07928642Courtesy of FORD MOTOR CO.
    15. NOTE: The sharp edges on the halfshaft splines can slice or puncture the oil seal. Use care when inserting the halfshaft into the transmission or damage to the seal may occur.
    Fig 12: Identifying LH Halfshaft In Transmission
    G07928643Courtesy of FORD MOTOR CO.
  15. Push the LH halfshaft into the transmission so the circlip locks into the differential side gear. Pull the halfshaft inner end to make sure the circlip is locked.
  16. Install the RH halfshaft in the transmission and engage the halfshaft splines with the transmission side gears and install the 2 RH halfshaft nuts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 13: Installing RH Halfshaft Assembly Into Transmission
      G07928644Courtesy of FORD MOTOR CO.
  17. Install the 2 wiring harness retainers on the RH halfshaft support studbolts.
    Fig 14: Locating Wiring Harness Retainers Of RH Halfshaft Support Studbolts
    G07928289Courtesy of FORD MOTOR CO.
  18. Install the subframe. Refer to UNI-BODY, SUBFRAME AND MOUNTING SYSTEM . Install the roll restrictor and the bracket on the transmission.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 15: Locating Roll Restrictor Bracket Bolts
      G07932105Courtesy of FORD MOTOR CO.
    19. NOTE: Rotate the engine in a clockwise direction only or engine damage will occur.
  19. Install 4 new torque converter nuts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 16: Locating Torque Converter Nuts
      G07928630Courtesy of FORD MOTOR CO.
  20. Install the starter insulator.
    Fig 17: Locating Starter Insulator
    G07928302Courtesy of FORD MOTOR CO.
  21. Install the starter. Refer to STARTING SYSTEM .
  22. Install the 3 top transmission-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 18: Locating Top Transmission-To-Engine Bolts
      G07928310Courtesy of FORD MOTOR CO.
  23. Position the transmission fluid cooler-warmer in place and install the 2 transmission fluid cooler-warmer bolts.
    • Tighten to 30 Nm (22 lb-ft).
      Fig 19: Locating Transmission Fluid Cooler-Warmer Bolts
      G07932101Courtesy of FORD MOTOR CO.
  24. If removed, inspect the transmission mounted transmission fluid cooler tube backing rings and seals for damage and install new backing rings or seals if necessary. Lubricate the transmission mounted transmission fluid cooler tube seals with clean transmission fluid and install the backing rings and seals on the transmission fluid cooler tubes.
    1. Seals (7D258).
    2. Backing rings (7J324).
      Fig 20: Identifying Transmission Fluid Cooler Tube Backing Rings And Seals
      G07932136Courtesy of FORD MOTOR CO.
  25. Position the transmission fluid cooler tubes in the transmission and install 2 new transmission fluid cooler tube bolts.
    • Tighten to 9 Nm (80 lb-in).
      Fig 21: Locating Transmission Fluid Cooler Tube Bolts
      G07932099Courtesy of FORD MOTOR CO.
  26. Position the transmission fluid temperature control valve on the main control cover studbolts and install the transmission fluid temperature control valve nuts. Install the retainer on the main control cover studbolt.
    • Tighten to 9 Nm (80 lb-in).
      Fig 22: Locating Transmission Fluid Temperature Control Valve Nuts And Retainer
      G07931969Courtesy of FORD MOTOR CO.
  27. Install the selector lever cable bracket and the 2 selector lever cable bracket bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 23: Locating Selector Lever Cable Bracket Bolts
      G07932139Courtesy of FORD MOTOR CO.
  28. Install the TCM bracket and the TCM bracket nut.
    • Tighten to 11 Nm (97 lb-ft).
      Fig 24: Locating TCM Bracket Nut
      G07932578Courtesy of FORD MOTOR CO.
  29. Connect the 3 battery cable pin-type retainers to the TCM bracket.
    Fig 25: Locating Battery Cable Pin-Type Retainers
    G07932577Courtesy of FORD MOTOR CO.
  30. Connect the TCM electrical connector.
    Fig 26: Locating TCM Electrical Connector
    G07932576Courtesy of FORD MOTOR CO.
  31. Install the battery and battery tray. Refer to BATTERY, MOUNTING AND CABLES .
  32. Install the ACL and the outlet pipe. Refer to INTAKE AIR DISTRIBUTION & FILTERING .
  33. Adjust the selector lever cable. Refer to AUTOMATIC TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS .
  34. Fill the transmission with clean transmission fluid. Refer to TRANSMISSION FLUID DRAIN AND REFILL .
  35. After completing the repairs, perform the Misfire Monitor Neutral Profile Correction procedure.
  36. If a new solenoid body is installed, the solenoid body strategy must be updated. Refer to SOLENOID BODY STRATEGY .
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