Removal And Installation: Transaxle: Installation

All vehicles 

1. Inspect the transmission fluid cooler tube backing rings and seals for damage and install a new backing rings or seals if necessary. Lubricate the transmission fluid cooler tube seals with clean automatic transmission fluid and install the backing rings and seals on the transmission fluid cooler tube.
   Fig 1: Identifying Transmission Fluid Cooler Tube Backing Rings And Seals

   Courtesy of FORD MOTOR CO.

   Item	Part Number	Description
   1	7D285	Seal
   2	7J324	Backing ring

2. Position the transmission fluid cooler thermal bypass valve and transmission fluid cooler tube assembly in place and install the transmission fluid cooler thermal bypass valve bracket nuts.
   • Tighten to 9 Nm (80 lb-in).
     Fig 2: Locating Transmission Fluid Cooler Thermal Bypass Valve And Transmission Fluid Cooler Tube Assembly

     Courtesy of FORD MOTOR CO.
3. Install new transmission fluid cooler tube bolts.
   • Tighten to 9 Nm (80 lb-in).
     Fig 3: Locating Transmission Fluid Cooler Tube Bolt

     Courtesy of FORD MOTOR CO.
4. Lubricate the torque converter pilot hub with grease and install the torque converter into the transaxle.
NOTE: Make sure that when installing the manual control lever it is fully seated onto the manual control lever shaft or damage to the manual control lever shaft will occur and the lever will come loose.
NOTE: Make sure to hold the manual control lever while tightening the manual control lever nut or damage to the manual control lever and park components will occur.
5. Install the manual control lever and nut.
   • Tighten to 18 Nm (159 lb-in).
     Fig 4: Locating Manual Control Lever And Nut

     Courtesy of FORD MOTOR CO.
NOTE: If the transaxle is not positioned on the dowel pins, damage to the transaxle can occur.
Fig 5: Locating Torque Converter Housing Dowel Pins
Courtesy of FORD MOTOR CO.
6. If the dowel pins were pulled out of the engine block during removal, install new dowel pins in the engine block.
7. Position the transaxle in place and install the 7 torque converter housing bolts.
   • Tighten to 48 Nm (35 lb-ft).
     Fig 6: Locating Torque Converter Housing Bolts

     Courtesy of FORD MOTOR CO.
8. Remove the Transmission Jack Adapter from the transaxle.
   Fig 7: Identifying Transmission Jack Adapter

   Courtesy of FORD MOTOR CO.
9. Install the transmission fluid cooler tubes in the transmission fluid cooler thermal bypass valve.
   Fig 8: Locating Transmission Fluid Cooler Tubes

   Courtesy of FORD MOTOR CO.
10. Install the 2 transmission fluid cooler tube secondary latches on the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.
    Fig 9: Locating Transmission Fluid Cooler Tube Secondary Latches

    Courtesy of FORD MOTOR CO.
NOTE: Use only the specified bolts for the torque converter. Standard length fasteners may bottom out and damage the torque converter clutch apply surface.
11. Install 3 new torque converter bolts (W714722).
    • Install the first torque converter bolt in the slotted hole on the flexplate.
    • Tighten to 55 Nm (41 lb-ft).
      Fig 10: Locating Torque Converter Bolt

      Courtesy of FORD MOTOR CO.
12. Install the inspection cover and the 2 fasteners.
    Fig 11: Locating Inspection Cover

    Courtesy of FORD MOTOR CO.

    All-Wheel Drive (AWD) vehicles 

13. Position the Power Transfer Unit (PTU) in place and install the 5 PTU-to-transaxle bolts.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 12: Locating Power Transfer Unit Bolts

      Courtesy of FORD MOTOR CO.
14. Position the PTU support bracket in place and install the 5 bolts.
    • Tighten to 70 Nm (52 lb-ft).
      Fig 13: Locating PTU Support Bracket Bolts

      Courtesy of FORD MOTOR CO.
NOTE: Make sure to tighten the 4 new nuts in the following sequence.
15. Install a new RH catalytic converter gasket, position the RH catalytic converter and tighten the 4 new nuts in the sequence shown in illustration.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 14: RH Catalytic Converter Nuts Tightening Sequence

      Courtesy of FORD MOTOR CO.
16. Connect the RH CMS electrical connector.
    Fig 15: Locating RH CMS Electrical Connector

    Courtesy of FORD MOTOR CO.
17. Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal and install the 4 bolts.
    • Tighten to 70 Nm (52 lb-ft).
      Fig 16: Locating Driveshaft Bolts

      Courtesy of FORD MOTOR CO.

    All vehicles 

18. Position the roll restrictor bracket on the transaxle and install the 3 bolts.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 17: Locating Roll Restrictor Bracket Bolts

      Courtesy of FORD MOTOR CO.
NOTE: Align the front subframe index marks to the body index marks made during removal.
19. Using the Powertrain Lift With Tilting Plate, position the subframe in place and install the 2 middle nuts.
    • Tighten to 150 Nm (111 lb-ft).
      Fig 18: Locating Middle Subframe Nut

      Courtesy of FORD MOTOR CO.
20. Install the 2 front subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
      Fig 19: Locating Front Subframe Nuts

      Courtesy of FORD MOTOR CO.
21. Position the subframe support brackets in place and loosely install the bolts.
    Fig 20: Locating Subframe Support Bracket Bolts

    Courtesy of FORD MOTOR CO.
22. Install the rear subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
      Fig 21: Locating Rear Subframe Nuts

      Courtesy of FORD MOTOR CO.
23. Tighten the subframe support bracket bolts.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 22: Locating Subframe Support Bracket Bolts

      Courtesy of FORD MOTOR CO.
24. Position the roll restrictor in place, install the 2 roll restrictor-to-transaxle through bolts.
    • Tighten to 115 Nm (85 lb-ft).
      Fig 23: Locating Roll Restrictor Through Bolts

      Courtesy of FORD MOTOR CO.
25. Install the roll restrictor heat shield and the 2 nuts.
    • Tighten to 9 Nm (80 lb-in).
      Fig 24: Locating Roll Restrictor Heat Shield Nuts

      Courtesy of FORD MOTOR CO.
NOTE: RH shown in illustration, LH similar.
26. Install the tie-rod ends and nuts.
    • Tighten to 48 Nm (35 lb-ft).
    • Install the cotter pins.
      Fig 25: Locating Tie-Rod Nut And Cotter Pin

      Courtesy of FORD MOTOR CO.
NOTE: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring can occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to SUPPLEMENTAL RESTRAINT SYSTEM .
27. Install the intermediate shaft onto the steering gear and install a new bolt.
    • Tighten to 23 Nm (17 lb-ft).
      Fig 26: Installing Intermediate Shaft Onto Steering Gear

      Courtesy of FORD MOTOR CO.
28. Using a new banjo bolt and 2 new seals, install the Power Steering Pressure (PSP) tube.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 27: Locating Power Steering Pressure Tube-To-Steering Gear Banjo Bolt And Seals

      Courtesy of FORD MOTOR CO.
29. Install the exhaust Y-pipe. For additional information, refer to EXHAUST SYSTEM .
30. Install the LH halfshaft and the intermediate shaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
31. Install the power steering cooler bracket bolt to the RH side of the subframe.
    • Tighten to 9 Nm (80 lb-in).
      Fig 28: Locating Power Steering Cooler Bracket Bolt

      Courtesy of FORD MOTOR CO.
32. Connect the power steering cooler hose.
    Fig 29: Locating Power Steering Cooler Hose Clamp

    Courtesy of FORD MOTOR CO.
33. Position the lower bumper on the subframe and install the 3 LH lower bumper-to-subframe nuts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 30: Locating LH Subframe-To-Lower Bumper Nuts

      Courtesy of FORD MOTOR CO.
34. Install the 3 RH lower bumper-to-subframe nuts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 31: Locating RH Subframe-To-Lower Bumper Nuts

      Courtesy of FORD MOTOR CO.
35. Install the front splash shield and install the screws and the pushpin fasteners.
    Fig 32: Locating Front Splash Shield, Pushpin Fasteners And Screws

    Courtesy of FORD MOTOR CO.
36. Position the RH fender splash shield in place and install the retainers.
    1. Install the screws.
    2. Install the pushpin fasteners.
       Fig 33: Identifying RH Fender Splash Shield Screws And Pushpin Fasteners

       Courtesy of FORD MOTOR CO.
37. Install the transaxle support insulator bracket, bolt and the 3 nuts.
    1. Tighten the transaxle support insulator bracket bolt to 80 Nm (59 lb-ft).
    2. Tighten the transaxle support insulator bracket nuts to 63 Nm (46 lb-ft).
       Fig 34: Locating Transaxle Support Insulator Bracket And Fasteners

       Courtesy of FORD MOTOR CO.
38. Install the transaxle support insulator through bolt.
    • Tighten to 175 Nm (129 lb-ft).
      Fig 35: Locating Transaxle Support Insulator Through Bolt

      Courtesy of FORD MOTOR CO.
39. Remove the Engine Support Bar and Engine Spreader Bar.
    Fig 36: Identifying Engine Support Bar And Engine Spreader Bar

    Courtesy of FORD MOTOR CO.
40. Remove the Engine Lift Eye from the LH cylinder head.
    Fig 37: Locating Engine Lifting Bracket On LH Cylinder Head

    Courtesy of FORD MOTOR CO.
41. If a new solenoid body was installed, wipe the surface of the existing solenoid body strategy tag on top of the transaxle case clean and install the new solenoid body strategy tag (supplied with the solenoid body service kit) over it.
    Fig 38: Locating Solenoid Body Strategy Tag

    Courtesy of FORD MOTOR CO.
42. Install the top 4 torque converter housing bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 39: Locating Top Torque Converter Housing Bolts

      Courtesy of FORD MOTOR CO.
43. Connect the transaxle electrical connector.
    Fig 40: Locating Transaxle Electrical Connector

    Courtesy of FORD MOTOR CO.
NOTE: The fuel tube retainer is damaged when it is removed from the transaxle stud and will no longer secure the fuel tubes to the transaxle stud. Failure to discard the old fuel tube retainer and install a new fuel tube retainer can result in damage to the fuel tubes.
Fig 41: Locating Fuel Tube Retainer
Courtesy of FORD MOTOR CO.
44. Install a new fuel tube retainer on the transaxle studbolt.
NOTE: Be sure the fuel tubes are installed in the fuel tube retainer in the same position and orientation as noted during removal. The fuel vapor tube is in the top groove of the retainer and the fuel supply tube is in the bottom groove of the retainer. Failure to install the fuel tubes in the correct position and orientation can result in the fuel tubes rubbing on components in the engine compartment causing damage to the fuel tubes.
45. Install the fuel supply tube and the fuel vapor tube in the fuel tube retainer.
    1. Fuel supply tube
    2. Fuel vapor tube
    3. Fuel tube retainer
       Fig 42: Installing Fuel Supply And Vapor Tube In Fuel Tube Retainer

       Courtesy of FORD MOTOR CO.
46. Install the starter studbolt.
    • Tighten to 26 Nm (19 lb-ft).
      Fig 43: Locating Starter Studbolt

      Courtesy of FORD MOTOR CO.
47. Install the wiring harness fastener on the starter motor studbolt.
    Fig 44: Locating Starter Motor Stud Bolt

    Courtesy of FORD MOTOR CO.
48. Connect the starter motor terminals and position the starter terminal boot over the battery cable terminal.
    1. Tighten to 12 Nm (106 lb-in).
    2. Tighten to 6 Nm (53 lb-in).
       Fig 45: Identifying Starter Motor Terminals

       Courtesy of FORD MOTOR CO.
49. Install the starter motor electrical terminal cover.
    Fig 46: Locating Starter Motor Electrical Terminal Cover

    Courtesy of FORD MOTOR CO.
50. Place the selector lever in DRIVE.
NOTE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket.
NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable retainer to click in place. Pull back on the selector lever cable to make sure that the selector lever is locked into the selector lever cable bracket.
Fig 47: Locating Selector Lever Cable Tabs And Bracket
Courtesy of FORD MOTOR CO.
51. Install the selector lever cable in the selector lever cable bracket.
52. Place the manual control lever in DRIVE.
    1. Rotate the manual control lever clockwise until it stops.
    2. Rotate the manual control lever counterclockwise one detent until it stops.
       Fig 48: Rotating Manual Control Lever

       Courtesy of FORD MOTOR CO.
53. Unlock the selector lever cable adjuster.
    1. Pry the latch up.
    2. Push the lock tab to slide it over.
       Fig 49: Sliding Selector Lever Cable Adjuster

       Courtesy of FORD MOTOR CO.
54. Slide the cable end forward or backward to align it with the manual control lever.
    Fig 50: Sliding Cable End Forward Or Backward

    Courtesy of FORD MOTOR CO.
55. With the adjuster locking tab released, connect the selector lever cable end to the manual control lever.
    Fig 51: Locating Manual Control Lever

    Courtesy of FORD MOTOR CO.
56. Slide the release tab back to lock the adjuster.
    Fig 52: Sliding Adjuster Tab To Lock Position

    Courtesy of FORD MOTOR CO.
57. Install the upper intake manifold. For additional information, refer to ENGINE - 3.5L .
58. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
59. Install the Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
60. Fill the power steering system. For additional information, refer to STEERING SYSTEM .
61. Fill with clean transmission fluid to the correct level. For additional information, refer to TRANSMISSION FLUID DRAIN AND REFILL .
62. If a replacement transaxle assembly is being installed or a new solenoid body is installed, the PCM will must be reflashed with a new solenoid body strategy and identification data file. For additional information, refer to SOLENOID BODY STRATEGY .
63. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.