Automatic Transmission - 6 Speed: Installation: Transaxle: Material

MATERIAL SPECIFICATION CHART

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.

CAUTION: 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 TRANSAXLE/TRANSMISSION COOLING .

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 Nm (41 lb-ft).
  
  Fig 1: Identifying Upper Transaxle Mount Retaining Bolts
  Courtesy of FORD MOTOR CO.
Prior to installing the transaxle, apply multi-purpose grease to the torque converter pilot hub.

Fig 2: Applying Multi-Purpose Grease To 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 Nm (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 Nm (89 lb-in).
  
  Fig 4: Connecting Transmission Fluid Cooler Tubes To Transaxle
  Courtesy of FORD MOTOR CO.
Connect the transmission fluid cooler tube bracket.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 5: Connecting Transmission Fluid Cooler Tube Bracket
  Courtesy of FORD MOTOR CO.
Install 4 new torque converter nuts.
- Tighten to 36 Nm (27 lb-ft).
  
  Fig 6: Identifying Torque Converter Nuts
  Courtesy of FORD MOTOR CO.
Install the lower rubber access plug and install the retaining pin.

Fig 7: Locating 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 At Catalytic Converter Bracket
Courtesy of FORD MOTOR CO.
Connect the heated oxygen sensor (HO2S) electrical connector.

Fig 9: Connecting Heated Oxygen Sensor (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: Positioning Subframe In Place
  Courtesy of FORD MOTOR CO.
Install the 2 bolts for the LH rear subframe mount.
- Tighten to 48 Nm (35 lb-ft).
  
  Fig 11: Installing Bolts For LH Rear Subframe Mount
  Courtesy of FORD MOTOR CO.
Install the 2 bolts for the RH rear subframe mount.
- Tighten to 48 Nm (35 lb-ft).
  
  Fig 12: Installing Bolts For RH Rear Subframe Mount
  Courtesy of FORD MOTOR CO.
Install 2 new bolts for the rear transaxle mount.
- Tighten to 90 Nm (66 lb-ft).
  
  Fig 13: Identifying Bolts For Rear Transaxle Mount
  Courtesy of FORD MOTOR CO.
Install the nut for the rear motor mount.
- Tighten to 70 Nm (52 lb-ft).
  
  Fig 14: Installing Nut For Rear Motor Mount
  Courtesy of FORD MOTOR CO.
Install the 2 bolts for the lower stabilizer mount.
- Tighten to 70 Nm (52 lb-ft).
  
  Fig 15: Installing Bolts For Lower Stabilizer Mount
  Courtesy of FORD MOTOR CO.
Install the nut for the front motor mount.
- Tighten to 70 Nm (52 lb-ft).
  
  Fig 16: Installing For Front Motor Mount
  Courtesy of FORD MOTOR CO.
Position the splash shield in place and install the 3 pushpins.

Fig 17: Positioning Splash Shield In Place
Courtesy of FORD MOTOR CO.
Connect the HO2S electrical connector to the subframe.

Fig 18: Connecting HO2S Electrical Connector To Subframe
Courtesy of FORD MOTOR CO.
Position the power steering rack in place. Install the bolts and nuts.
- Tighten to 133 Nm (98 lb-ft).
  
  Fig 19: Positioning Power Steering Rack In Place
  Courtesy of FORD MOTOR CO.
Position the power steering line in place and install the 4 bolts.
- Tighten to 7 Nm (62 lb-in).
  
  Fig 20: Positioning Power Steering Line In Place
  Courtesy of FORD MOTOR CO.
Connect the wire harness to the LH front of the subframe.

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

Fig 22: Positioning Lower Radiator Hose In Place
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: Identifying 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 Tools In Lifting Hook Near EGR Valve
Courtesy of FORD MOTOR CO.
Remove the special tools from the RH (rear) cylinder head.

Fig 25: Installing Special Tools To RH (Rear) Cylinder Head
Courtesy of FORD MOTOR CO.
Remove the special tools from the LH (front) cylinder head.

Fig 26: Installing Special Tools To LH (Front) Cylinder Head
Courtesy of FORD MOTOR CO.
Remove the special tools.

Fig 27: Identifying Special Tools To Support Engine Assembly
Courtesy of FORD MOTOR CO.
Install new bolts for the catalytic converter.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 28: Locating Bolts For Catalytic Converter
  Courtesy of FORD MOTOR CO.
Remove the upper half of the lifting hook.

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

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

Fig 32: Connecting KS Wire Harness To Transaxle
Courtesy of FORD MOTOR CO.
Install the KS.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 33: Locating Knock Sensor
  Courtesy of FORD MOTOR CO.
Install the heat shield over the KS.

Fig 34: Identifying Heat Shield Over Knock Sensor
Courtesy of FORD MOTOR CO.
If equipped, connect the engine block heater.

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

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

Fig 44: Installing PCV Hose
Courtesy of FORD MOTOR CO.
Connect the vacuum hose to the throttle body.

Fig 45: Connecting Vacuum Hose To Throttle Body
Courtesy of FORD MOTOR CO.
Position the bracket for the power steering hose and install the bolt.
- Tighten to 7 Nm (62 lb-in).
  
  Fig 46: Positioning Bracket For Power Steering Hose
  Courtesy of FORD MOTOR CO.
Connect the ground wire.
- Tighten to 12 Nm (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 Nm (41 lb-ft).
  
  Fig 48: Positioning Roll Restrictor
  Courtesy of FORD MOTOR CO.
Install the starter motor.
- Tighten to 26 Nm (19 lb-ft).
  
  Fig 49: Installing Starter Motor
  Courtesy of FORD MOTOR CO.
Connect the 2 starter motor electrical connectors.
- Tighten the larger nut to 12 Nm (9 lb-ft).
- Tighten the smaller nut to 5 Nm (44 lb-in).
  
  Fig 50: Identifying Starter Motor Electrical Connectors
  Courtesy of FORD MOTOR CO.
Install the electrical cover for the starter motor electrical connectors.

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

Fig 52: Locating Wire Harness At 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: Installing 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: Locating Wire Harness At 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: Installing Shift Cable Bracket And Bolts
  Courtesy of FORD MOTOR CO.
Connect the electrical connector to the shift cable bracket.

Fig 58: Locating Electrical Connector At 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: Identifying Transaxle Roll Restrictor Bar Bolts
  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 Nm (35 lb-ft).
  
  Fig 61: Identifying Upper Roll Restrictor
  Courtesy of FORD MOTOR CO.
Install the cowl panel grille. For additional information, refer to FRONT END BODY PANELS .
Remove the transmission fluid fill plug.

Fig 62: Locating Fluid Fill Plug
Courtesy of FORD MOTOR CO.
Fill the transaxle with clean automatic transmission fluid.
Install the fluid fill plug.
- Tighten to 39 Nm (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 INTAKE AIR DISTRIBUTION & FILTERING .
Install the battery tray and the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
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°C-80°C (158°F-176°F) using the scan tool.

Fig 64: Identifying Fluid Fill Plug

Courtesy of FORD MOTOR CO.

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