Installation

1. Proper installation of the torque converter requires full engagement of the converter hub in the transaxle. To accomplish this, the torque converter must be pushed and at the same time rotated until the converter seats.

Torque Converter Engagement Check:

2. Place a straightedge on the transaxle flange as shown. With the torque converter properly installed, there will be a 10 mm (7/16 inch) air gap between the straightedge and torque converter.
3. With torque converter properly installed, place transaxle on jack and secure with safety chain or belt.





4. Position transaxle and jack under vehicle.

CAUTION: During this move, to avoid damage, do not allow the transaxle to get into a nose-down position as this will cause the torque converter to move forward and disengage from the transaxle.

5. Raise transaxle into place and align with engine.
6. Looking through inspection hole in transaxle-to-engine separator plate, align torque converter studs with mating holes in flywheel.
7. Move transaxle towards engine. Install lower transaxle-to-engine retaining bolts. Tighten bolts to 55-68 Nm (41-50 ft. lbs.).
8. Rotate torque converter to install four torque converter-to-flywheel retaining nuts to 33-40 Nm (25-29 ft. lbs.).
9. Remove transmission jack.
10. Install metal inspection cover to transaxle-to-engine separator plate.





11. Install electrical connector to turbine shaft speed (TSS) sensor.
12. Install front sub-frame.
13. Install LH and RH engine support insulator through bolts. Do not tighten to specification at this time.
14. Install lower radiator support brackets to front sub-frame. Tighten bolts to 27 Nm (19 ft. lbs.).
15. Install transaxle cooler inlet and outlet lines.
16. Connect speedometer cable and electrical connector to vehicle speed sensor (VSS).
17. Install exhaust system.





18. Install a new circlip to the LH transaxle halfshaft. Install LH transaxle halfshaft.





19. Install A/C suction accumulator/drier bracket to front sub-frame. Tighten screws to 6-8 Nm (53-71 inch lbs.).





20. Install intermediate halfshaft, bearing and bearing retainer.
21. Install RH transaxle halfshaft.
22. Install LH and RH front suspension lower arms to front wheel knuckles. Insert new pinch bolts and nuts and tighten the nuts to 83 Nm (61 ft. lbs.).
23. Connect LH and RH stabilizer bar links to front shock absorber.
24. If equipped, install ABS wiring loom retainer to stabilizer bar link stud. Tighten retaining nuts to 47 Nm (35 ft. lbs.).





25. Install LH and RH tie rod ends to front wheel knuckles. Tighten tie rod end retaining nuts to 31-47 Nm (23-35 ft. lbs.). Tighten to minimum specified torque, continue tightening to nearest cotter pin slot and insert new cotter pins.
26. Install front wheels. Tighten lug nut to 85 Nm (62 ft. lbs.) in an alternate pattern.





27. Lower vehicle. Connect steering yoke to steering gear shaft.
28. Install upper transaxle-to-engine retaining bolts. Tighten bolts to 55-68 Nm (41-50 ft. lbs.).
29. Remove safety wire retaining radiator to upper support.
30. Reinstall all wiring retaining clips that were disconnected for transaxle removal.
31. Raise the engine and transaxle assembly into position using the three-bar engine support adjusters.
32. Install engine and transmission support insulator to LH front fender apron. Tighten bolts to 54-75 Nm (40-55 ft. lbs.).
33. Install new lock nuts retaining engine and transmission support insulator to transaxle. Tighten to 54-75 Nm (40-55 ft. lbs.).
34. Install front engine support insulator. On 2.5L vehicles, install power steering line retaining bracket to front engine support insulator. Tighten new lock nuts to 77-103 Nm (56-76 ft. lbs.).
35. Remove Rotunda 3-Bar Engine Support 014-00750 or equivalent from vehicle.
36. Install transmission range (TR) sensor.
37. Connect the transaxle 10-pin harness connector. Install the TR sensor electrical connector. Connect wire loom retaining clips as necessary.
38. Position starter motor. Install retaining bolts and tighten to 20-27 Nm (15-20 ft. lbs.).





39. Install shift cable mounting bracket. Tighten bolts to 20-25 Nm (15-19 ft. lbs.). Install shift cable to manual lever by pressing onto stud until a click is heard.
40. Install battery tray, battery and hold-downs. Tighten bolts to 8-10 Nm (71-88 inch lbs.).





41. Install new front suspension shock absorber upper mounting nuts. Tighten to 46 Nm (33 ft. lbs.).
42. Fill power steering pump remote fluid reservoir.
43. Connect battery cables.
44. Fill transaxle to proper level with Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or MERCON equivalent.
45. With engine at operating temperature, recheck transaxle fluid level. Check for leaks. MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4.



46. Road test vehicle and check shift points and shift quality.