Installation

Special Tool(s)


1. NOTE: The torque converter hub must fully engage with the transaxle pump drive gear.





Check the installation depth of the torque converter.
^ Lay a steel straightedge on the automatic transaxle flange.
^ Check the installation depth between the transaxle flange and the torque converter centering spigot for the correct clearance: 12 mm.
^ Apply a thin layer of High-temperature grease meeting Ford Specification ESD-M1C220-A or equivalent to the centering spigot bore on the torque converter.

2. CAUTION: The torque converter is heavy. Install the torque converter holding tools before raising the transaxle.

CAUTION: 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.





Install special tool.





3. Using the Hi-Lift Transmission Jack and the CD4E transaxle adapter raise and position the transaxle into place.
^ Remove the special tool T97T-7902-A

4. NOTE: The special tool T97T-7902-A must be removed.





Install the front bellhousing bolts.





5. Install the lower bellhousing bolts.





6. Install the four torque converter nuts.
^ Rotate the torque converter to gain access to remaining nuts.
^ Install torque converter rubber.

CAUTION: To avoid to damage joints and boots, do not bent the inner halfshaft joint by more than 18 degrees, the outer one by not more than 45 degrees.

7. NOTE: Do not damage the oil seal.





Install the right-hand halfshaft and intermediate shaft.





8. Install a new snap-ring.

CAUTION: To avoid to damage joints and boots, do not bent the inner halfshaft joint by more than 18 degrees, the outer one by not more than 45 degrees.

9. NOTE: Do not damage the oil seal. Check that the snap-ring engages correctly.





Install the left-hand halfshaft.

10. CAUTION: Do not loosen connector cooler inlet to transaxle.





Position and install the lower transaxle cooling tube

11. CAUTION: Do not loosen connector cooler inlet to transaxle.





Position and install the transaxle lower line

12. NOTE: Do not tighten the bolt





Install the rear roll restrictor through bolt

13. WARNING: Support the subframe using Rotunda Powertrain Lift. Place wooden block approximately 40 inches in length secured to lift under sub-frame.

NOTE: Do not tighten the bolts





Install the sub-frame





14. Install the transaxle cooler line brackets.
^ Position the suction accumulator (A/C), if equipped.





15. Install the power steering oil hoses to the subframe (one nut and two bolts).





16. Install the steering gear (two bolts) (left-hand side shown).





17. Install the steering gear heat shield.





18. Align the sub-frame and tighten the bolts.
1. Install Subframe Locating Pins.
2. Align the subframe with the locating holes in the body.
3. Install the subframe bolts working diagonally.





19. Replace the front roll restrictor with special tool.
1. Install special tool.
2. Install the bolts.
3. Install the through bolt.
20. Lower the vehicle.





21. Tighten the rear transaxle support bracket nuts.
22. Raise and support the vehicle.





23. Install the right-hand engine support insulator.





24. Tighten the rear roll restrictor through bolt.





25. Replace the special tool with the rear engine support isolator.
1. Install the through bolt.
2. Install the bolts.





26. Install the control arm.





27. Install the front exhaust pipe and the rear Three-Way Catalytic Converter (TWC).
^ Install the gaskets.
^ Hang up the TWC into the rubber hangers.





28. Connect the front exhaust pipe and the TWC.
^ Install the gaskets.





29. Connect the Heated Oxygen (H02S) connector.
^ Separate the cable ties.
Vehicles with air conditioning





30. Install the suction accumulator (A/C) bolts.
All Vehicles





31. Install the bumper bracket.





32. Install the bolts and right side, front inner splash shield.





33. Install the bolts and right side, rear inner splash shield.





34. Install the radiator splash shield.
^ Install the bolts and clips.
35. Lower the vehicle.





36. Install both front wheels (right hand side shown).





37. Install the selector cable.
1. Install the selector cable to the selector lever.
2. Install the bracket

38. NOTE: Install harness from transaxle.





Connect the Vehicle Speed Sensor (VSS) connector (shown from below ).





39. Connect the plug from the Turbine Shaft Speed sensor (TSS) (shown from below).
^ Clip the cable.





40. Install the upper bellhousing bolts (four bolts).





41. Remove the special tools.





42. Connect the starter motor and install the starter motor bracket.





43. Install the water pump pulley cover.
^ Attach the engine coolant hose and install the bolts.





44. Connect the following electrical connectors to the automatic transaxle assembly.
1. Ground cable
2. Automatic transaxle control
3. Transmission Range switch (TR switch)
4. Wiring harness retaining clip

45. NOTE: Use an Allen wrench to stop the piston rod from turning.





Tighten the suspension strut locknuts (right-hand side shown).





46. Tighten the suspension strut locknuts with a torque wrench (right-hand side shown).





47. Remove the radiator supports.





48. Fill up the transaxle with MERCON(R) multi-purpose automatic transmission. MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4.
49. When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.
50. Install the battery tray.
51. Fill and bleed the power steering system.