Installation

CAUTION: The torque converter must remain at the correct installation depth throughout the entire installation procedure.

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 surface of the converter hub.





1. On automatic transaxle vehicles measure the installation depth of the torque converter between the flange of the torque converter housing and the torque converter.

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





2. Install the transaxle on the engine and install the upper transaxle bolts.





3. Install the lower bolts.





4. Connect the following electrical connectors.
1 Position the harness.
2 Turbine shaft speed (TSS) sensor.
3 Transaxle control connector.
4 Transaxle range sensor.





5. Connect the vehicle speed sensor (VSS).





6. Connect the front heated oxygen sensor (H02S).





7. Connect the starter motor wiring.
- Install the S terminal nut.
- Install the B terminal nut.





8. Lower the engine/transaxle onto the subframe using a suitable floor crane.

NOTE:
- Do not allow the weight of the engine and transaxle to be placed on the RH or LH powertrain roll restrictors. This can overstress and/or damage the roll restrictors leading to increased engine vibration in the vehicle passenger compartment.
- If the powertrain fixture is not available, use a suitable lift and blocks of wood to support the engine/transaxle assembly.





9. Lower the engine/transaxle assembly on to the subframe and support the weight of the engine and transaxle on the power train fixture or suitable lifting device not having a collapsed height of greater than twenty-eight inches.

NOTE: Do not tighten the bolt at this time.





10. Install the RH engine roll restrictor through bolt.
11. Install the front half shafts.
12. Position and raise the engine transaxle assembly on the power train fixture or lower the vehicle over the assembly.





13. Install a three bar engine support to the engine lifting eyes and fully support the weight of the powertrain to unload the front and rear engine/transaxle mounts.
14. Remove the lifting device or powertrain fixture (if used).





15. Install the 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.

NOTE: Install only new self-locking nuts.





16. Install but do not tighten the rear transaxle mount nuts.

NOTE: Use only new self-locking nuts.





17. Install but do not tighten the upper front engine mount.





18. Replace the LH engine roll restrictor with the Powertrain Alignment Tool.
1 Install the Powertrain Alignment Tool.
2 Install the bolts.
3 Install the through bolt.

NOTE: An attempt should be made to position the nuts as previously installed using nut witness marks.





19. Tighten the upper front engine mount nuts.
1 Tighten the nuts.
2 Install the wire retainer.





20. Tighten the rear transaxle mount nuts.





21. Remove the three bar engine support.

NOTE: Verify that the RH engine roll restrictor is centered in the transaxle bracket and in perfect front-to-rear alignment before tightening the through bolt.





22. Tighten the RH engine roll restrictor bolts.
- If necessary, loosen RH roll restrictor to subframe mounting bolts and reposition the roll restrictors.

NOTE: Verify that the LH engine roll restrictor is centered in the transaxle bracket and in perfect front-to-rear alignment before tightening the through bolt.





23. Replace the Powertrain Alignment Tool with the LH engine roll restrictor.
1 Install the through bolt.
2 Install the bolts.





24. Connect the A/C accumulator line.





25. Connect the heater control vacuum hose.





26. Connect the upper radiator hose.





27. Connect the upper intake vacuum supply lines.
- Push down on plastic collar to install vacuum lines.





28. On automatic transaxle vehicles connect the shifter cable.
1 Position the cable.
2 Install the bolts.
3 Connect the cable.





29. On manual transaxle equipped vehicles, connect the shifter cables.
1 Install the nuts.
2 Connect the cables.





30. Install the power steering lines.
1 Position the power steering line.
2 Connect the power steering line.
3 Install the ground strap.
4 Install the bolt.





31. Install the coolant reservoir hoses.





32. Connect the powertrain control module (PCM).
1 Connect the PCM.
2 Install the bolt.
3 Install the ground strap.





33. Install the power steering reservoir.





34. Connect the bulkhead connector.
1 Position the connector.
2 Install the connector bolt.





35. Connect the accelerator and the speed control cables.
1 Connect the accelerator cable.
2 Connect the speed control cable.





36. On SVT equipped vehicles connect the accelerator and speed control cables.
1 Connect the accelerator and speed control cables.
2 Clip the cables into the bracket.





37. Connect the fuel lines and install the safety clips.
38. Install the air intake box assembly.





39. Install the water pump pulley cover.
1 Install the cover.
2 Install the bolts.
3 Position the hose in the clip.





40. Connect the steering shaft.
1 Position the steering shaft.
2 Install the pinch bolt.





41. Install the LH and RH strut pinch bolts.





42. Install the LH and RH brake calipers.
1 Install the brake caliper.
2 Install the bolts.
3 Position the bolt cover.





43. Install the LH and RH wheel speed sensors.
1 position the wheel speed sensor.
2 Install the bolt.
3 Install the retainer.





44. Connect the LH and RH stabilizer bar link rods.
1 Position the stabilizer bar link rod.
2 Install the nut.





45. Install the LH and RH front wheels.





46. Install the A/C accumulator drier.





47. On automatic transaxle vehicles install the torque converter nuts.





48. On automatic transaxle vehicles install the flywheel access cover.





49. Install the bumper to subframe brackets.
1 Install the push pins.
2 Install the bolts.





50. Install the front RH inner splash shield.





51. Install the front RH, rear inner splash shield.





52. Connect the heater core hoses.





53. Install the LH and RH lower radiator support brackets.
1 Position the bracket.
2 Install the bolts.





54. For manual transaxle vehicles, install the converter pipe.
1 Position the converter pipe.
2 Install the hanger.
3 Install the nuts.





55. For automatic transaxle vehicles, install the flex pipe.
1 Position the flex pipe.
2 Install the hanger.
3 Install the nuts.





56. Install the exhaust crossover pipe.
1 Install the crossover pipe hanger nut.
2 Install the exhaust manifold nuts.





57. Connect the heated oxygen sensors (H02S).





58. Connect the A/C condenser line.





59. Connect the A/C compressor electrical connector.





60. Connect the lower radiator hose.





61. On automatic transaxle vehicles install the lower transaxle cooler line.





62. Connect the power steering cooler lines.





63. Install the transaxle drain plug.





64. Install the engine oil filter.
- Lubricate the filter gasket with WSE-M2C908-A engine oil prior to installation.





65. Install the lower radiator shroud.
1 Install the lower radiator shroud.
2 Install the five push pins.
3 Install the bolts.





66. Install the battery cables in the retaining clips.





67. Connect the battery cables.
68. Charge the A/C system.
69. Fill the cooling system.
70. Fill the transaxle with fluid.
71. Fill and bleed the power steering system.
72. Fill the engine with oil.
- Use Ford super premium 5W-30 motor oil meeting Ford specification WWS-M2C153-F.

NOTE: If excessive powertrain vibration is noted, the powertrain alignment should be checked by verifying equal clearance on either side of the engine roll restrictors. Verify that the powertrain alignment procedure was performed correctly.

73. Road test the vehicle and check all fluid levels.