Installation

1. Lightly lubricate torque converter hub with Ford Multi-Purpose Grease (or equivalent). Align torque converter with transaxle. Rotate and push converter inward to seat splined hub into pump.

2. Position High-Lift Transmission Jack or equivalent under vehicle.

3. NOTE: Make sure engine harness is on outside of shift cable bracket.

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

4. Secure transaxle to engine by installing two lower bolts to transaxle. Tighten bolts to 55-68 Nm (41-50 lb-ft).

5. Install two bolts to front of transaxle at right engine insulator bracket. Tighten bolts to 53-72 Nm (39- 53 lb-ft).

6. Install left and right halfshafts to transaxle.

7. Lower High-Lift Transmission Jack or equivalent and remove it from under vehicle.

8. Connect VSS and TSS sensor connectors.

9. Remove caps from cooling lines and install cooling lines to transaxle. Install safety clips.

10. Position Powertrain Lift or equivalent and sub4rame under vehicle.

11. Raise sub4rame assembly until left and right engine support insulator studs are centered and rear transaxle insulator is centered.

Position ball joints to steering knuckles and align steering gear with subframe.

12. Raise sub4rame and install Rotunda Sub4rame Alignment Pin Set or equivalent. Install four bolts and tighten them to 77-103 Nm (57-76 lb-ft). Remove subframe alignment pin set and Powertrain Lift or equivalent from under vehicle.

13. Install two engine insulator-to-subframe nuts. Install transaxle insulator-to-subframe nut. Tighten nuts to 77-103 Nm (57-76 lb/ft).

14. Install two nuts at steering gear to subframe. Tighten nuts to 113-133 Nm (84-98 lb-ft).

15. Position power steering filter to bracket and securely install retainers to subframe. Connect coolant hose to locator at front of subframe.

16. Install four new torque converter nuts by rotating converter, using crankshaft pulley bolt. Tighten nuts to 27-46 Nm (20-34 lb-ft).

17. NOTE: Align starter holes prior to tightening down cover.

Position inspection shield dust cover and install bolt. Tighten bolt to 9-12 Nm (80-106 lb-in).

18. Position starter motor and install two bolts. Tighten bolts to 21-29 Nm (15-21 lb-ft).

19. Install locking clip nut to transaxle eyelet for exhaust mounting bracket. Position catalytic converter assembly and loosely install one transaxle bolt to support exhaust.

20. Install four nuts to exhaust manifold. Tighten bolt at exhaust support to transaxle. Tighten nuts and bolt to 34-46 Nm (25-33 lb-ft).

21. Using a new gasket, position converter outlet to flex tube and install bolts and nuts. Tighten retainers to 34-46 Nm (25-33 lb-ft). Securely tighten nut at exhaust slotted bracket to front of transaxle.

22. Connect three HO2S connectors and locators at front and rear of subframe.

23. Install pinch bolts and nuts at lower ball joints. Tighten retainers to 68-92 Nm (51-67 lb-ft).

24. Connect left and right tie rod ends to front wheel knuckles. Install tie rod end nuts. Tighten nuts to 47-63 Nm (35-46 lb-ft), then continue to nearest cotter pin slot and install new cotter pins.

25. Connect left and right stabilizer bar links to strut assemblies. Install nuts and tighten to 30-40 Nm (23-29 lb-ft).

26. Position air deflector and securely install screws.

27. Install front wheel assemblies. Tighten wheel nuts to 115-142 Nm (85-102 lb-ft).

28. Lower vehicle.

29. Remove Three-Bar Engine Support or equivalent and Engine Lifting Brackets where necessary.

30. Position coil pack bracket and install bolts at left rear cylinder head. Tighten bolts to 40-55 Nm (30-40 lb-ft). Connect number four, five, and six spark plug wires to coil.

31. Position ground wire and install bolt at right front cylinder head. Tighten bolt to 40-55 Nm (30-40 lb-ft).

32. Position manifold brace at right rear cylinder head and install bolt. Tighten bolt to 40-55 Nm (30-40 lb-ft). Tighten upper bolt at intake manifold to 8-12 Nm (71-106 lb-in).

33. Install three bolts and one stud retaining transaxle to engine. Tighten retainers to 53-72 Nm (39-53 lb-ft). Position ground wire and starter harness locator to starter stud and securely install nut.

34. Install transaxle insulator-to-subframe nut. Tighten nut to 77-103 Nm (57-75 lb-ft).

35. Connect shift cable to shift lever and bracket. Securely install nut. Position speed control servo, install upper nut and securely tighten lower nut.

36. Connect TR sensor, 10-pin harness, and H025 connectors. Position harness and install harness locators at shift cable bracket and transaxle fill tube. Install bolt to harness locator at top of transaxle.

37. Place gearshift lever in OVERDRIVE position (D position for vehicles equipped with Transmission Control Switch [TCS]). Hang a weight of 1.4 kg (3 lb) on gearshift lever to verify lever is located firmly on OVERDRIVE position (D position on vehicles equipped with TCS detent).

38. Loosen manual control lever4o-control cable retaining nut. Move transaxle manual control lever to OVERDRIVE position (D position on vehicles equipped with a TCS, second detent from most rearward position). Tighten retaining nut to 17-23 Nm (13-17 lb-ft).

39. Check operation of transaxle in each transmission range position~ Make sure park mechanism and TR sensor are functioning properly.

40. Install air filter, position air cleaner, tighten clamp at throttle body, and connect two clips.

41. Connect MAF sensor connector, IAT sensor connector, and crankcase vent tubes to air cleaner assembly.

42. Install battery and hold down. Tighten retainer to 7-10 Nm (62-89 lb-in).

43. Connect positive and negative battery cables.

44. Fill transaxle with specified quantity and type of fluid.

45. Check operation of transaxle.

46. Check toe setting and adjust if necessary.