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Automatic Transmission - 6 Speed: Installation: Transaxle

Special Tools

Illustration Tool Name Tool Number
GF0016982
 Lifting Bracket Set, Engine (3.0L 4V-V6) 134-00243 or equivalent
GF0016983
 Engine Lifting Bracket Set 307-1140
GF0009357
 Support Bar, Engine 303-290A
GF0009355
 Adapters for 303-290A 303-290A-01
GF0009356
 Adapter for 303-290A (Support Leg) 303-290A-03A
GF0016984
 Adapter for 303-290A (Lifting Hook) 303-290A-12
Material

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 article.

  1. If removed, clean the rear transaxle mount bolts using a wire brush and apply new threadlocker to the threads.
  2. If installing a new transaxle, install the rear transaxle mount.
    • Tighten to 55 Nm (41 lb-ft).
    3. Fig 1: Identifying Upper Transaxle Mount Retaining Bolts
    G03991478Courtesy of FORD MOTOR CO.
  3. Prior to installing the transaxle, apply multi-purpose grease to the torque converter pilot hub.
  4. Position the transaxle to the back of the engine.
  5. Install the 3 transaxle-to-engine bolts.
    • Tighten to 40 Nm (30 lb-ft).
    6. Fig 2: Locating Transaxle-To-Engine Bolts
    G03990545Courtesy of FORD MOTOR CO.
  6. Using new O-ring seals, connect the transmission fluid cooler tubes to the transaxle.
    • Tighten to 10 Nm (89 lb-in).
    7. Fig 3: Locating Transmission Fluid Cooler Tubes At Transaxle
    GF0017773Courtesy of FORD MOTOR CO.
  7. Connect the transmission fluid cooler tube bracket.
    • Tighten to 10 Nm (89 lb-in).
    8. Fig 4: Locating Transmission Fluid Cooler Tube Bracket
    G03991687Courtesy of FORD MOTOR CO.
  8. Install 4 new torque converter nuts.
    • Tighten to 36 Nm (27 lb-ft).
    9. Fig 5: Locating Torque Converter Nuts
    G03990970Courtesy of FORD MOTOR CO.
  9. Install the lower rubber access plug and install the retaining pin.
    10. Fig 6: Locating Pushpins & Rubber Access Plug
    G03990969Courtesy of FORD MOTOR CO.
  10. Position the catalytic converter in place and loosely install the bolt for the bracket.
    11. Fig 7: Locating Bolt For Catalytic Converter Bracket
    G03991042Courtesy of FORD MOTOR CO.
  11. Connect the heated oxygen sensor (HO2S) electrical connector.
    12. Fig 8: Locating Heated Oxygen Sensor (HO2S) Electrical Connector
    G03990967Courtesy of FORD MOTOR CO.
  12. Using a suitable powertrain lift, position the subframe in place and install the 4 bolts.
    • Tighten to 90 Nm (66 lb-ft).
    13. Fig 9: Locating Subframe Bolts
    G03990966Courtesy of FORD MOTOR CO.
  13. Install the 2 bolts for the LH rear subframe mount.
    • Tighten to 48 Nm (35 lb-ft).
    14. Fig 10: Identifying Bolts For LH Rear Subframe Mount
    G03990963Courtesy of FORD MOTOR CO.
  14. Install the 2 bolts for the RH rear subframe mount.
    • Tighten to 48 Nm (35 lb-ft).
    15. Fig 11: Locating RH Rear Subframe Mount Bolts
    G03990964Courtesy of FORD MOTOR CO.
  15. Install 2 new bolts for the rear transaxle mount.
    • Tighten to 90 Nm (66 lb-ft).
    16. Fig 12: Identifying Bolts For Rear Transaxle Mount
    G03990748Courtesy of FORD MOTOR CO.
  16. Install the nut for the rear motor mount.
    • Tighten to 70 Nm (52 lb-ft).
    17. Fig 13: Locating Nut For Rear Motor Mount
    G03990961Courtesy of FORD MOTOR CO.
  17. Install the 2 bolts for the lower stabilizer mount.
    • Tighten to 70 Nm (52 lb-ft).
    18. Fig 14: Locating Bolts For Lower Stabilizer Mount
    G03990960Courtesy of FORD MOTOR CO.
  18. Install the nut for the front motor mount.
    • Tighten to 70 Nm (52 lb-ft).
    19. Fig 15: Locating Front Motor Mount Nut
    G03990959Courtesy of FORD MOTOR CO.
  19. Position the splash shield in place and install the 3 pushpins.
    20. Fig 16: Locating Splash Shield Pushpins
    G03990958Courtesy of FORD MOTOR CO.
  20. Connect the HO2S electrical connector to the subframe.
    21. Fig 17: Locating HO2S Electrical Connector
    G03990957Courtesy of FORD MOTOR CO.
  21. Position the power steering rack in place. Install the bolts and nuts.
    • Tighten to 133 Nm (98 lb-ft).
    22. Fig 18: Locating Bolts & Nuts For Power Steering Rack
    G03990956Courtesy of FORD MOTOR CO.
  22. Position the power steering line in place and install the 4 bolts.
    • Tighten to 7 Nm (62 lb-in).
    23. Fig 19: Locating Power Steering Line To Subframe Bolt
    G03990954Courtesy of FORD MOTOR CO.
  23. Connect the wire harness to the LH front of the subframe.
    24. Fig 20: Locating Wire Harness
    G03991029Courtesy of FORD MOTOR CO.
  24. Position the lower radiator hose in place and connect the retainers.
    25. Fig 21: Locating Lower Radiator Hose
    G03990953Courtesy of FORD MOTOR CO.
  25. Install the LH and RH stabilizer bar link into the struts and install new nuts.
    • Tighten to 55 Nm (41 lb-ft).
    26. Fig 22: Identifying Stabilizer Bar Link Nuts
    G03990245Courtesy of FORD MOTOR CO.
  26. Remove the special tool from the lifting hook near the EGR valve.
    27. Fig 23: Identifying Special Tools (303-1140, 303-290A-12)
    G03990017Courtesy of FORD MOTOR CO.
  27. Remove the special tools from the RH (rear) cylinder head.
    28. Fig 24: Identifying Special Tools (134-00243, 303-290A-12)
    G03990016Courtesy of FORD MOTOR CO.
  28. Remove the special tools from the LH (front) cylinder head.
    29. Fig 25: Identifying Special Tools (134-00243, 303-290A-12)
    G03990950Courtesy of FORD MOTOR CO.
  29. Remove the special tools.
    30. Fig 26: Identifying Special Tools To Support Engine Assembly
    G03990949Courtesy of FORD MOTOR CO.
  30. Install new bolts for the catalytic converter.
    • Tighten to 40 Nm (30 lb-ft).
    31. Fig 27: Locating Catalytic Converter Bolts
    G03990947Courtesy of FORD MOTOR CO.
  31. Remove the upper half of the lifting hook.
    32. Fig 28: Identifying Upper Half Of Lifting Hook
    G03990011Courtesy of FORD MOTOR CO.
  32. Remove the lower half of the lifting hook.
    33. Fig 29: Identifying Lower Half Of Lifting Hook
    G03990010Courtesy of FORD MOTOR CO.
  33. Install the transaxle-to-engine bolt.
    • Tighten to 40 Nm (30 lb-ft).
    34. Fig 30: Locating Transaxle-To-Engine Bolt
    GF0017130Courtesy of FORD MOTOR CO.
  34. Connect the KS wire harness to the transaxle.
    35. Fig 31: Locating Knock Sensor Wire Harness
    G03991013Courtesy of FORD MOTOR CO.
  35. Install the KS.
    • Tighten to 10 Nm (89 lb-in).
    36. Fig 32: Locating Knock Sensor
    G03990667Courtesy of FORD MOTOR CO.
  36. Install the heat shield over the KS.
    37. Fig 33: Identifying Knock Sensor Heat Shield
    G03990937Courtesy of FORD MOTOR CO.
  37. If equipped, connect the engine block heater.
    38. Fig 34: Locating Block Heater Electrical Connector
    G03990550Courtesy of FORD MOTOR CO.
  38. Position the power steering hose in place and install the bolt.
    • Tighten to 7 Nm (62 lb-in).
    39. Fig 35: Locating Power Steering Hose Bolt
    G03990941Courtesy of FORD MOTOR CO.
  39. Tighten the catalytic converter bolt to the bracket.
    • Tighten to 40 Nm (30 lb-ft).
    40. Fig 36: Locating Bolt For Catalytic Converter Bracket
    G03991042Courtesy of FORD MOTOR CO.
  40. Install the LH and RH halfshafts. For additional information, refer to FRONT DRIVE HALFSHAFTS article.
  41. 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).
    42. Fig 37: Identifying Nuts For Catalytic Converter Pipe
    G03990732Courtesy of FORD MOTOR CO.
  42. Install 2 new nuts for the rear exhaust pipe.
    • Tighten to 40 Nm (30 lb-ft).
    43. Fig 38: Identifying Nuts For Rear Exhaust Pipe
    G03990731Courtesy of FORD MOTOR CO.
  43. Install 2 new nuts for the front exhaust pipe.
    • Tighten to 40 Nm (30 lb-ft).
    44. Fig 39: Locating Front Exhaust Pipe Nuts
    G03990730Courtesy of FORD MOTOR CO.
  44. Install the 4 upper transaxle bolts.
    • Tighten to 40 Nm (30 lb-ft).
    45. Fig 40: Locating Upper Transaxle Bolts
    GF0017793Courtesy of FORD MOTOR CO.
  45. Install the bolt for the power steering line.
    • Tighten to 7 Nm (62 lb-in).
    46. Fig 41: Locating Power Steering Line Bolt
    G03990945Courtesy of FORD MOTOR CO.
  46. Connect the vapor tube to the canister purge valve.
    47. Fig 42: Locating Vapor Tube
    G03990216Courtesy of FORD MOTOR CO.
  47. Install the PCV hose.
    48. Fig 43: Locating Positive Crankcase Ventilation (PCV) Hose
    G03990916Courtesy of FORD MOTOR CO.
  48. Connect the vacuum hose to the throttle body.
    49. Fig 44: Locating Vacuum Hose At Throttle Body
    G03990917Courtesy of FORD MOTOR CO.
  49. Position the bracket for the power steering hose and install the bolt.
    • Tighten to 7 Nm (62 lb-in).
    50. Fig 45: Locating Bracket For Power Steering Hose
    G03990996Courtesy of FORD MOTOR CO.
  50. Connect the ground wire.
    • Tighten to 12 Nm (9 lb-ft).
    51. Fig 46: Locating Ground Wire
    GF0017125Courtesy of FORD MOTOR CO.
  51. Clean the roll restrictor bolts using a wire brush and apply new threadlock and sealer to the threads.
  52. Position the roll restrictor in place and install the bolts.
    • Tighten to 55 Nm (41 lb-ft).
    53. Fig 47: Locating Roll Restrictor Bolts
    GF0017121Courtesy of FORD MOTOR CO.
  53. Install the starter motor.
    • Tighten to 26 Nm (19 lb-ft).
    54. Fig 48: Locating Starter Bolts
    GF0017792Courtesy of FORD MOTOR CO.
  54. 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).
    55. Fig 49: Identifying Starter Motor Electrical Connectors
    G03990920Courtesy of FORD MOTOR CO.
  55. Install the electrical cover for the starter motor electrical connectors.
    56. Fig 50: Identifying Electrical Cover For Starter Motor Electrical Connectors
    G03990919Courtesy of FORD MOTOR CO.
  56. Connect the wire harness to the roll restrictor.
    57. Fig 51: Locating Wiring Harness At Roll Restrictor Bolts
    G03990915Courtesy of FORD MOTOR CO.
  57. Clean the 4 roll restrictor bracket bolts using a wire brush and apply new threadlock and sealer to the threads.
  58. Install the roll restrictor bracket and install 4 new bolts.
    • Tighten to 40 Nm (30 lb-ft).
    59. Fig 52: Locating Roll Restrictor Bracket Bolts
    G03990914Courtesy of FORD MOTOR CO.
  59. Connect the lower wire harness to the transaxle.
    60. Fig 53: Locating Lower Wire Harness
    G03990913Courtesy of FORD MOTOR CO.
  60. Connect the wire harness to the transaxle.
    61. Fig 54: Locating Wire Harness Retainers At Transaxle
    G03990911Courtesy of FORD MOTOR CO.
  61. Connect the transmission control module (TCM) electrical connector.
    62. Fig 55: Identifying Transmission Control Module Electrical Connector
    G03991767Courtesy of FORD MOTOR CO.
  62. Install the shift cable bracket and bolts.
    • Tighten to 25 Nm (18 lb-ft).
    63. Fig 56: Locating Bolts For Shift Cable Bracket
    GF0017791Courtesy of FORD MOTOR CO.
  63. Connect the electrical connector to the shift cable bracket.
    64. Fig 57: Locating Electrical Connector At Shift Cable Bracket
    G03990909Courtesy of FORD MOTOR CO.
    CAUTION: Be careful not to bend the manual control lever when installing the shift cable.
  64. Connect the shift cable end.
    65. Fig 58: Locating Shift Cable End
    G03991743Courtesy of FORD MOTOR CO.
  65. Clean the 4 roll restrictor brace bolts using a wire brush and apply new threadlock and sealer to the threads.
  66. Position the roll restrictor brace in place and install the bolts.
    • Tighten to 55 Nm (41 lb-ft).
    67. Fig 59: Identifying Transaxle Roll Restrictor Bar Bolts
    G03989189Courtesy of FORD MOTOR CO.
  67. Clean the upper roll restrictor bolt using a wire brush and apply new threadlock and sealer to the threads.
  68. Install the upper roll restrictor.
    • Tighten to 48 Nm (35 lb-ft).
    69. Fig 60: Locating Upper Roll Restrictor Bolt
    G03989188Courtesy of FORD MOTOR CO.
  69. Install the cowl panel grille. For additional information, refer to FRONT END BODY PANELS article.
  70. Remove the transmission fluid fill plug.
    71. Fig 61: Locating Transmission Fluid Fill Plug
    G03991680Courtesy of FORD MOTOR CO.
  71. Fill the transaxle with clean automatic transmission fluid.
  72. Install the fluid fill plug.
    • Tighten to 39 Nm (29 lb-ft).
    73. Fig 62: Locating Transmission Fluid Fill Plug
    G03991680Courtesy of FORD MOTOR CO.
  73. Install the air cleaner and outlet tube. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING article.
  74. Install the battery tray and the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
  75. Remove the fluid level indicator and make sure that the transaxle has fluid in it.
  76. Reflash the TCM to the latest level calibration available.
  77. 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.
  78. Wipe the fluid level indicator cap and remove the fluid level indicator.
  79. Wipe the fluid level indicator with a clean cloth.
    80. 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.
  80. 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.
    81. Fig 63: Locating Fluid Level Indicator
    G03991682Courtesy of FORD MOTOR CO.
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