Manual Transaxle (G6M): Installation: Transaxle

SPECIAL TOOLS

	Powertrain Lift 300-OTC1585AE or equivalent
	Support Bar, Engine 303-F072 or equivalent
	Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

MATERIAL SPECIFICATIONS

Item	Specification
Premium Long-Life Grease XG-1-C or XG-1-K (US); CXG-1-C (Canada)	ESA-M1C75-B
SAE 75W-90 API GL-4 Gear Oil XT-4-QGL	WSS-M2C203-A1
Threadlock and Sealer TA-25	WSK-M2G351-A5

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.

NOTE: Wipe off excess grease. The splines should have a thin film of grease only. Excess grease can contaminate the clutch facing and affect clutch function.
1. Apply a very small amount of grease on the input shaft splines.
2. Secure the transaxle to a suitable transmission jack with a safety strap. Raise and position the transaxle behind the engine.
3. Install the clutch housing-to-oil pan bolt.
   • Tighten to 48 Nm (35 lb-ft).
     Fig 1: Locating Clutch Housing-To-Oil Pan Bolt

     Courtesy of FORD MOTOR CO.
4. Install the 2 oil pan-to-clutch housing bolts.
   • Tighten to 48 Nm (35 lb-ft).
     Fig 2: Locating Oil Pan-To-Clutch Housing Bolts

     Courtesy of FORD MOTOR CO.
5. Install the 4 lower transaxle-to-engine bolts.
   • Tighten to 48 Nm (35 lb-ft).
6. Apply threadlock and sealer to the threads and install the 2 transmission lower mount nuts and bolt to the transaxle. Do not tighten the fasteners at this time.
7. Position the clutch slave cylinder to the clutch release arm and install the bolts.
   • Tighten to 20 Nm (177 lb-in).
     Fig 3: Locating Clutch Slave Cylinder Bolts

     Courtesy of FORD MOTOR CO.
8. Install the clutch tube hydraulic line bracket bolts.
   • Tighten to 22 Nm (16 lb-ft).
     Fig 4: Locating Clutch Tube Hydraulic Line Bracket Bolts

     Courtesy of FORD MOTOR CO.
9. Install the starter motor. For additional information, refer to STARTING SYSTEM .
10. Place the subframe assembly on the Powertrain Lift and raise the subframe into the installed position.
    Fig 5: Installing Subframe Assembly Using Powertrain Lift

    Courtesy of FORD MOTOR CO.
NOTE: LH shown in illustration, RH similar.
11. Install the front subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
      Fig 6: Locating Front Subframe Nut

      Courtesy of FORD MOTOR CO.
NOTE: LH shown in illustration, RH similar.
Fig 7: Locating Subframe Bracket And Bolt
Courtesy of FORD MOTOR CO.
12. Position the subframe brackets and install the bolts finger-tight.
NOTE: LH shown in illustration, RH similar.
13. Install the subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
      Fig 8: Locating Subframe Nut

      Courtesy of FORD MOTOR CO.
NOTE: LH shown in illustration, RH similar.
Fig 9: Locating Subframe Bracket-To-Body Bolts
Courtesy of FORD MOTOR CO.
14. Tighten the subframe bracket-to-body bolts to 103 Nm (76 lb-ft).
NOTE: LH shown in illustration, RH similar.
15. Install the stabilizer bar links and nuts on the struts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 10: Locating Stabilizer Bar Link Nut

      Courtesy of FORD MOTOR CO.
16. Install the 2 roll restrictor bracket bolts.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 11: Locating Roll Restrictor Bracket Bolts

      Courtesy of FORD MOTOR CO.
17. Install the Electronic Power Assist Steering (EPAS) system wiring harness ground and the bolt behind the RH splash shield.
    • Tighten to 12 Nm (106 lb-in).
      Fig 12: Locating EPAS System Wiring Harness Ground And RH Splash Shield Bolt

      Courtesy of FORD MOTOR CO.
18. Attach the EPAS system wiring harness pin-type retainer to the subframe under the LH fender splash shield.
    Fig 13: Locating EPAS System Wiring Harness Pin-Type Retainer To Subframe Under LH Fender Splash Shield

    Courtesy of FORD MOTOR CO.
19. Attach the 2 EPAS system wiring harness pin-type retainers to the subframe.
    Fig 14: Locating EPAS System Wiring Harness Pin-Type Retainer

    Courtesy of FORD MOTOR CO.
20. Connect the 2 in-line EPAS system electrical connectors at the front of the subframe.
    Fig 15: Locating In Line Electronic Power Assist Steering (EPAS) System Electrical Connectors

    Courtesy of FORD MOTOR CO.
21. Install the LH halfshaft and the intermediate shaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
22. Install the LH splash shield and the 6 pin-type retainers (4 shown in illustration).
    Fig 16: Locating LH Splash Shield And Pin-Type Retainers

    Courtesy of FORD MOTOR CO.
23. Position the LH fender splash shield and install the 4 screws.
    Fig 17: Locating LH Fender Splash Shield Mounting Screws

    Courtesy of FORD MOTOR CO.
24. Install the RH splash shield and the 6 pin-type retainers (4 shown in illustration).
    Fig 18: Locating RH Splash Shield And Pin-Type Retainers

    Courtesy of FORD MOTOR CO.
25. Position the RH fender splash shield and install the 4 screws.
    Fig 19: Locating RH Fender Splash Shield Mounting Screws

    Courtesy of FORD MOTOR CO.
26. Install the exhaust flexible pipe. For additional information, refer to EXHAUST SYSTEM .
27. Connect the reverse lamp switch electrical connector.
28. Connect the Output Shaft Speed (OSS) sensor electrical connector.
    Fig 20: Locating Output Shaft Speed Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
29. Fill the transaxle with clean gear oil. For additional information, refer to TRANSAXLE DRAINING AND FILLING .
30. Install the splash shield and the 7 bolts.
    • Tighten to 9 Nm (80 lb-in).
      Fig 21: Locating Splash Shield With Mounting Bolts

      Courtesy of FORD MOTOR CO.
NOTE: The steering gear/dash seal must be fully seated in the steering valve tower groove before the retaining clips are fully engaged into the body. If the steering gear/dash seal is not seated to the steering gear valve tower groove and the clips are not fully engaged to the body, water and foreign material may enter the passenger compartment and damage the vehicle interior can occur.
31. Install the steering gear/dash seal.
    • Apply hand force to the center of the seal, install the steering gear/dash seal onto the steering gear valve tower until the seal is fully seated in the valve tower groove. Install the steering gear/dash seal until the retaining clips are fully engaged into the body.
      Fig 22: Locating Steering Gear/Dash Seal

      Courtesy of FORD MOTOR CO.
32. Install the steering column shaft onto the steering gear and install a new bolt.
    • Tighten to 20 Nm (177 lb-in).
      Fig 23: Locating Steering Column Shaft Mounting Bolts

      Courtesy of FORD MOTOR CO.
33. Install the steering joint cover and the 2 nuts.
    Fig 24: Locating Steering Joint Cover And Nuts

    Courtesy of FORD MOTOR CO.
NOTE: If one or both of the mount studs were removed or came out, do not reinstall the old stud(s). Install a new stud(s). Make sure they are properly seated in the case.
34. Tighten the transaxle rear support insulator nuts and bolt to specification.
    • Tighten to 80 Nm (59 lb-ft).
35. Install the 3 upper transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
36. Attach the wire harness to the transaxle.
37. Remove the Engine Support Bar.
    Fig 25: Removing Engine Support Bar (303-F072)

    Courtesy of FORD MOTOR CO.
38. Install the gearshift and shift cables onto the transaxle bracket and gearshift control assembly. Make sure the cables are engaged in the shift bracket and fully installed on the gearshift control assembly.
    Fig 26: Locating Transaxle Bracket Shift Cables

    Courtesy of FORD MOTOR CO.
39. Install the battery tray and battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
40. Install the Air Cleaner (ACL) assembly. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - 2.5L .
41. If the input shaft was replaced, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.
42. Check the vehicle for normal operation.