Installation

1. Lightly lube the torque converter hub with Ford Multi-purpose Grease.

2. Install the transmission jack under the vehicle.

3. Install a jack stand with a block of wood under the front of the engine oil pan.

4. Raise the transaxle to the engine and align the torque converter studs with the flexplate.

5. Secure the transaxle by installing two lower engine-to-transaxle bolts and three oil pan-to-transaxle bolts. Tighten the bolts to 40 Nm (30 lb-ft).

6. Install three bolts to the front of the transaxle, at the left engine insulator bracket. Tighten the bolts to 62 Nm (46 lb-ft).

7. Replace the right halfshaft circlip. Install both halfshafts to the transaxle.

8. Lower the transmission jack and remove it from under the vehicle. Remove the jack stand.

9. Connect the TSS sensor connector and insert the harness pushpin into the transaxle fluid tube bracket.

10. Remove the caps from the cooling lines, connect the lines, and install the safety clips.

11. Install the starter motor and tighten the bolts to 25 Nm (18 lb-ft). Position the negative battery cable to the starter stud and securely install the nut. Install the positive battery cable and the retaining nut to the starter solenoid B-terminal. Tight the nut to 12 Nm (91 b-ft).

Note: Be careful to push it straight on and make sure that the connector locks in position with a notable click or detent. Connect the starter motor solenoid connector. Replace the starter motor solenoid terminal cover.

12. Position the lift and subframe under the vehicle.

13. Raise the subframe assembly until approximately 4 inches of clearance remains from the subframe to the body.

14. Install the screw retaining the power steering hose to the subframe, near the secondary Air Injection Reactor (AIR) pump.

15. Position the AIR pump into place. Install the nuts and bolt. Connect the electrical connectors. Tighten the retainers to 10 Nm (89 lb-in).

16. Install a 19mm (3/4 inch) outside diameter pipe (or similar tool) into the front subframe and body alignment holes. Raise the subframe assembly until the left and right engine support insulator studs are centered and the rear transaxle insulator is centered. Position the ball joints into the lower control arms and align the steering gear into the subframe.

17. Loosely install the four front subframe-to-body bolts. Align the subframe to the body. Tighten the bolts to 91 Nm (67 lb-ft).

18. Lower and remove the powertrain lift from under the vehicle. Remove the alignment pins from the subframe.

19. Install the two engine insulator-to-subframe nuts. Tighten the nuts to 91 Nm (67 lb-ft).

20. Install the two nuts retaining the steering gear to the subframe. Tighten the nuts to 123 Nm (91 lb-ft).

21. Install the power steering line bracket and securely install the retainers to the subframe. Connect the coolant hose locator to the front of the subframe.

22. Install four new torque converter nuts. Rotate the converter, using the crankshaft pulley bolt. Tighten the nuts to 37 Nm (27 lb-ft).

23. Install the four crankshaft pulley cover pushpins. Position the transmission housing cover and install the plastic screws.

24. Install the locking clip nut to the transaxle eyelet for the exhaust mounting bracket. Install the dual catalytic converter assembly in place and install the transaxle bolt to support the exhaust. Install the four nuts to the exhaust manifold. Tighten the nuts and bolt to 34-46 Nm (25-33 lb-ft). Tighten the nut at the exhaust slotted bracket to the front of the transaxle.

25. Using a new gasket, position the converter outlet to the flex tube. Install the bolts and nuts. Tighten the retainers to 40 Nm (30 lb-ft).

26. Disconnect the wire securing the tie rod ends to the brake hose brackets. Connect four HO2S connectors and locators to the front and rear of the subframe. Insert the HO2S connector pushpins into the power steering line bracket.

27. Install the lower ball joint nuts. Tighten the nuts to 80 Nm (59 lb-ft).

28. Position the front air deflector and securely install the screws.

29. Lower the vehicle.

30. Install the transaxle insulator-to-subframe nut. Tighten the nut to 123 Nm (91 lb-ft). Install the AIR tube bracket and securely install the retaining nut. Install the hose to the tube.

31. Connect the tie rod ends to the front wheel knuckles and install the nuts. Tighten the nuts to 47 Nm (35 lb-ft). If necessary, continue to the next cotter pin slots and install new cotter pins.

32. Connect the left and right stabilizer bar links to the strut assemblies. Install the nuts and tighten them to 35 Nm (26 lb-ft).

33. Remove the ties securing the suspension height sensors to the upper struts. Connect the sensors to the upper and lower ball studs.

34. Install the front wheel assemblies. Tighten the wheel nuts to 128 Nm (94 lb-ft).

35. Lower the vehicle.

36. Remove Three Bar Engine Support D88L-6000-A from the vehicle.

37. Remove the front engine support bracket.

38. Raise the vehicle.

39. Remove the right rear engine lifting bracket lower bolt and loosen the top two bolts.

40. Lower the vehicle.

41. Remove the remaining engine lifting bracket bolts and remove the bracket.

42. Install the three bolts retaining the transaxle to the engine. Tighten the bolts to 62 Nm (46 lb-ft).

43. Install the transaxle fluid level indicator, connect the shift cable to the shift cable bracket, install the transaxle manual control lever, and install the retaining nut.

44. NOTE: The floor gearshift lever must be held in the rearward position using a constant force of 3 lb (or equivalent) while the linkage is being adjusted.

Place the gearshift lever in the DRIVE position, against the rearward stop. Loosen the manual control lever-to-control cable retaining nut. Move the transaxle manual control lever to the DRIVE position (second detent from the rearmost position) and tighten the nut to 20 Nm (15 lb-ft).

45. Check the operation of the transaxle in each range position. Make sure the park mechanism and the TR sensor are functioning properly.

46. Install the drain tube. Install the left lower cowl, then the right lower cowl. Securely install the screws to the bulkhead.

47. Install the wiper motor connector and grommet through the cowl top extension.

48. Install the two nuts retaining the vacuum valve block to the lower cowl support. Tighten the nuts to 8 Nm (71 lb-in).

49. Install the left upper cowl vent screen, then the right screen. Install the plastic screws and six retaining clips to the panel.

50. Install the wiper pivot arm assemblies to the pivot shafts and install the nuts. Tighten the nuts to 35 Nm (26 lb-ft). Install the wiper output arm covers.

51. Connect the 42-pin connector, position the 42-pin harness bracket, and install the bolt to the top of the transaxle case. Connect the TR sensor connector and the 10-pin harness.

52. Install the battery cable harness locator bracket in place on the stud near the upper radiator hose and securely install the nut. Install the harness pushpin into the battery cable harness locator bracket.

53. Install the air cleaner lid, tighten the clamp at the throttle body, and connect the two clips. Connect the MAF sensor connector, IAT connector, and crankcase vent tubes to the air cleaner assembly.

54. Remove the prop rod and connect the hood support rods. Connect the washer fluid line.

55. Install the battery tray. Install the air cleaner housing to the tray, clip the constant control relay module to the tray, and install the bolts. Tighten the bolts to 10 Nm (89 lb-in).

56. Install the battery, battery cover, and hold-down. Tighten the retainer to 8 Nm (71 lb-in).

57. Connect the positive and negative battery cables.

58. Fill the transaxle with the specified quantity and type of fluid.

59. Check the operation of the transaxle.

60. Check the toe setting and adjust as necessary.