Installation

1. Install transaxle to Rotunda Transmission Jack 014-00210 or equivalent. Secure transaxle following tool manufacturer's instructions.
2. Apply a film of Ford Spline Grease F5RZ-19590-MA or equivalent meeting Ford specification ESD-M1C220-A to the input shaft splines.
3. Install RH engine support insulator bracket to transaxle case. Tighten bolts to 84 Nm (62 ft. lbs.). Install gear shift stabilizer bar mounting bracket to RH transaxle support insulator bracket stud and transaxle case. Tighten the nut and bolt to 38-51 Nm (28-38 ft. lbs.).
4. Align and install transaxle to engine. Use an 18 mm socket to rotate the engine while installing transaxle so that input shaft splines will mate with clutch disc.
5. install two lower side and then two lower transaxle retaining bolts. Tighten to 40 Nm (30 ft. lbs.).
6. Install starter motor and lower bolt. Tighten retaining bolt to 48 Nm (35 ft. lbs.).
7. Lower vehicle.





8. Using a floor jack and block of wood at engine and transaxle mating area, raise engine and transaxle assembly into position. Adjust Three-Bar Engine Support D88L-6000-A or equivalent to retain engine and transaxle.
9. Install upper transaxle retaining bolts. Tighten to 38-51 Nm (28-38 ft. lbs.).
10. Install nuts retaining front engine support bracket. Tighten nuts to 83 Nm (61 ft. lbs.).
11. Install upper starter motor retaining bolt. Tighten to 48 Nm (35 ft. lbs.).





12. Install ground strap to transaxle retaining bolt. Connect backup lamp switch connector.
13. Install engine and transaxle support insulator.
14. Raise vehicle.
15. Install LH and RH halfshafts and intermediate shaft.
16. Install front sub-frame. Do not install front wheels at this time.





17. Install two screws retaining suction accumulator/drier to front sub-frame.
18. Install shift rod to transaxle gearshift shaft. Install retaining bolt and tighten to 19-25 Nm (14-18 ft. lbs.).





19. Install gear shift control stabilizer bar to its mounting stud. Install nut and tighten to 38-51 Nm (28-38 ft. lbs.).
20. Install underbody heat shield under shift control and retainers.





21. Connect VSS electrical connector. Install speedometer cable.
22. Install catalytic converter to exhaust manifold and exhaust pipe using new gaskets.
23. Install support bracket strap to catalytic converter and engine.
24. Install bracket to catalytic converter and intermediate halfshaft bearing bracket.





25. Install lower radiator air deflector.





26. Install the belt pulley cover by sliding it up under the front fender splash shield.
27. Install front fender splash shield retaining screws. Install belt pulley cover screws.
28. Fill transaxle with 2.6 liters (5.5 pints) of Motorcraft MERCON(r) Multi-Purpose Automatic Transmission Fluid or equivalent meeting MERCON(r) specification and 30 ml (1.0 oz) Ford Friction Modifier F3TZ-19B546-MA meeting Ford specification WSP-M2C196-A or equivalent. MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4.





29. Install front wheels. Tighten lug nuts to 85 Nm (63 ft. lbs.).
30. Lower vehicle.
31. Remove Three-Bar Engine Support D88L-6000-A or equivalent.
32. Install wire loom retainers disconnected for transaxle removal.





33. Install clutch slave cylinder hydraulic pressure quick-disconnect fitting onto the supply line by pushing it on. Install retaining clip.
34. Install rubber inspection cover to clutch housing. Install hydraulic line into retaining grommet.





35. Remove front shock absorber upper mounting nuts. Replace with new locknuts and tighten to 46 Nm (34 ft. lbs.).
36. Install battery and battery cables.
37. Install mass air flow sensor and air cleaner outlet tube with resonator. Install engine air cleaner (ACL).
38. Remove wire retaining radiator.
39. Road test vehicle. If shift quality is abnormal, adjust shift linkage. If clutch pedal feels spongy or transaxle shifts hard, bleed clutch hydraulic system.