Transaxle Installation

Transaxle









Installation

1. Install the transaxle.

2. Install the 4 lower clutch housing-to-engine bolts (3 shown).
- Tighten to 48 Nm (35 lb-ft).






3. Using the special tools, lower the transaxle.





4. Install the transaxle support insulator, the 2 transaxle support insulator bolts and the 2 nuts.
- Tighten the 2 bolts to 90 Nm (66 lb-ft).

- Tighten the 2 nuts to 125 Nm (92 lb-ft).






5. Install the ground wire and bolt onto the transaxle.
- Tighten to 25 Nm (18 lb-ft).






6. Attach the clutch hydraulic hose to the transaxle retainer.





7. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury.

NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.

Install the clutch hydraulic hose onto the transaxle and install the clip.






8. Install the 2 LH clutch housing-to-engine bolts.
- Tighten to 48 Nm (35 lb-ft).






9. NOTE: The roll restrictor bolts are different lengths, make sure the roll restrictor bolts are in the correct location using the marks made during removal.
Install the roll restrictor bracket, roll restrictor and the roll restrictor bolts.
Loosely install the 2 roll restrictor bolts and the 2 roll restrictor bracket bolts at this time.

- Only tighten the top 2 roll restrictor bracket bolts.
- Tighten the to 48 Nm (35 lb-ft).






10. Tighten the roll restrictor bolts.
1. Tighten the roll restrictor bolt to 70 Nm (52 lb-ft).

2. Tighten the roll restrictor-to-transaxle bracket bolt to 70 Nm (52 lb-ft).






11. Attach the Heated Oxygen Sensor (HO2S) bracket to the transaxle and install the HO2S (Heated Oxygen Sensor) bracket nut.
- Tighten to 25 Nm (18 lb-ft).






12. Using a new exhaust flange gasket and nuts, connect the exhaust flange to the exhaust.
- Tighten to 48 Nm (35 lb-ft).






13. Install the LH halfshaft into the transaxle.

14. Install the LH ball joint into the knuckle.

15. Install the new LH ball joint bolt and nut.
- Tighten to 48 Nm (35 lb-ft).






16. Install the brake hose retainer and bolt on the LH strut.
- Tighten to 25 Nm (18 lb-ft).






17. Install the RH intermediate shaft assembly into the transaxle.

18. Install the new bearing retainer strap and shield (if equipped).
- Install the strap on the studs.

- Position the shield (if equipped) on the studs.






NOTICE: Install the bearing retainer strap on the bracket studs before the shield, and tighten the nuts evenly in stages (alternating from top to bottom) or incorrect bearing clampload may occur causing component damage.

19. Install the new bearing retainer strap nuts.
- Tighten to 6 Nm (53 lb-in).

- Tighten to 6 Nm (53 lb-in).

- Tighten to 25 Nm (18 lb-ft).

- Tighten to 25 Nm (18 lb-ft).






20. Install the RH ball joint into the knuckle.

21. Install the new RH ball joint bolt and nut.
- Tighten to 48 Nm (35 lb-ft).






22. Install the brake hose retainer and bolt on the RH strut.
- Tighten to 25 Nm (18 lb-ft).






23. Install the front wheels.

24. Install the 2 top clutch housing-to-engine bolts.
- Tighten to 48 Nm (35 lb-ft).






25. Install the 4 clutch housing-to-engine bolts (3 shown).
- Tighten to 48 Nm (35 lb-ft).






26. Install the transaxle vent hose on the cooling fan housing.





27. Attach the transaxle vent hose to the hose retainer.





28. Connect the reverse light switch electrical connector.





29. Install the wiring harness bracket and wiring harness bracket bolt to the transaxle.
- Tighten to 25 Nm (18 lb-ft).






30. Install the battery tray bracket and the 3 battery tray bracket nuts.
- Tighten to 25 Nm (18 lb-ft).






31. Attach the wiring harness to the battery tray bracket.





32. Install the battery tray and 3 battery tray bolts.
- Tighten to 10 Nm (89 lb-in).






33. Connect the 3 PCM electrical connectors.





34. Install the PCM cover and the PCM cover bolt.
- Tighten to 6 Nm (53 lb-in).






35. Install the cowl assembly.

36. Install the battery.

37. Fill the transaxle with transmission fluid. For additional information, refer to Transaxle Draining and Filling Procedures.

38. Bleed the clutch hydraulic system.

39. Adjust the gearshift cables.