Installation

Special Tools:

1. Raise and support the vehicle.

2. Measure the installation depth of the torque converter between the torque converter flange housing and the torque converter.

NOTE:
- The torque converter hub must fully engage with the transaxle pump drive gear.
- Apply a thin coat of petroleum jelly to the inner and outer surfaces of the torque converter hub.

3. Install Torque Converter Holding tool.

CAUTION:
- The torque converter is heavy. Install the torque converter holding tools before raising the transaxle.
- The torque converter must remain at the correct installation depth throughout the whole installation procedure.

NOTE: The torque converter studs must be aligned with the flywheel holes before any transaxle to engine bolts are installed.

4. Raise and Position the transaxle into place.

5. Install the lower transaxle to engine bolts.

NOTE: The Torque Converter Holding Tool must be removed.

6. Lower the vehicle.

NOTE: Remove the High Lift Jack.

7. Connect the Vehicle Speed Sensor (VSS) electrical connector.
8. Install the VSS cable.
9. Raise the vehicle.
10. Install the halfshaft.

11. Connect the Turbine Shaft Speed (TSS) sensor electrical connector.

12. Install the four subframe bolts.
1 Install Subframe Locating Pins.
2 Align the subframe with the locating holes in the body.
3 Install the subframe bolts working diagonally.
13. Loosely install the rear roll restrictor.

14. Install but do not tighten the rear transaxle mounting nuts.

15. Install but do not tighten the front roll restrictor bracket.

16. Replace the front roll restrictor with Power Alignment Gauge.
1 Install Power Alignment Gauge.
2 Install the bolts.
3 Install the through bolt.

17. Tighten the rear transaxle support bracket nuts.

18. Replace Powertrain Alignment Gauge with the rear engine support isolator.
1 Install the through bolt.
2 Install the bolts.

19. Position and install the transaxle cooler upper line.

20. Position and install the transaxle lower line.

21. Install the steering knuckle.

22. Position the power steering gear heat shield and install the six bolts.

23. Install the transaxle cooler line brackets.

24. Install the air condition suction accumulator/drier bolts.

NOTE: If equipped with air conditioning.

25. Install the exhaust as necessary.

26. Install the lower radiator support brackets.

27. Install the radiator air deflector.
1 Position the air deflector.
2 Install the bolts.
3 Install the clips.
28. Lower the vehicle.

29. Install the side bell housing bolts.
30. Install the Transmission Range (TR) sensor.

31. Install the torque converter nuts.
- Install torque converter inspection- cover.

32. Install the upper bell housing to engine bolts.

CAUTION: The torque converter must remain at the correct installation depth through the whole installation procedure.

33. Install transaxle wiring harness.
1 Install the battery ground cable
2 Install the solenoid pack electrical connector.
3 Install the Transmission Range (TR) sensor electrical connector.
4 Install the wiring harness retaining clip.

34. Remove the engine support bracket.
35. Install the starter motor.
36. Install the air cleaner assembly.

37. Install the transaxle vent tube.

NOTE: Ensure the transaxle vent tube is not kinked or crimped, and vent tube is properly orientated with vent tube end positioned downward.

38. Fill the transaxle using Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid or equivalent meeting MERCON specifications.
- Make sure engine is at normal operating temperature and filled to specified level. MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4.