Installation

Special Tools:

Installation
1. Lightly lube torque converter hub with Ford Multi-Purpose Grease D0AZ- 19584-AA or equivalent meeting Ford specification ESB-M1C93-B. Align torque converter with transaxle. Rotate and push converter inward to seat splined hub into pump.
2. Position High Lift Transmission Jack 014-00924 or equivalent under vehicle.

3. NOTE: Make sure engine harness is on outside of shift cable bracket.

Raise transaxle up to engine and align torque converter studs with flex plate.
4. Secure transaxle to engine by installing two lower bolts to transaxle. Tighten bolts to 53-72 Nm (39-53 ft. lbs.).
5. Install two bolts to front of transaxle at right engine insulator bracket. Tighten bolts to 53-72 Nm (39-53 ft. lbs.).
6. Install left and right halfshafts to transaxle.
7. Lower High Lift Transmission Jack 014-00942 or equivalent and remove it from under vehicle.
8. Connect the VSS and TSS sensor connectors.
9. Remove caps from cooling lines and install cooling lines to transaxle. Install safety clips.
10. Position Powertrain Lift 014-00765 or equivalent and sub-frame under vehicle.
11. Raise sub-frame assembly until the left and right engine support insulator studs are centered and rear transaxle insulator is centered. Position ball joints to steering knuckles and align steering gear with sub-frame.
12. Raise sub-frame and install Sub-frame Alignment Pin Set T94P-2100-AH. Install four bolts and tighten them to 77-103 Nm (57-75 ft. lbs.). Remove sub-frame alignment pin set and Powertrain Lift 014-00765 or equivalent from under vehicle.
13. Install two engine insulator-to-sub-frame nuts. Install transaxle insulator-to-sub-frame nut. Tighten nuts to 77-103 Nm (57-75 ft. lbs.).
14. Install two nuts at steering gear to sub-frame. Tighten nuts to 113-133 Nm (84-98 ft. lbs.).
15. Position power steering filter to bracket and securely install retainers to sub-frame. Connect coolant hose to locator at front of sub-frame
16. Install four new torque converter nuts by rotating converter, using crankshaft pulley bolt. Tighten nuts to 27-46 Nm (20-34 ft. lbs.).

17. NOTE: Align starter holes prior to tightening down cover.

Position inspection shield dust cover and install bolt. Tighten bolt to 9-12 Nm (80-106 inch lbs.).
18. Position starter motor and install two bolts. Tighten bolts to 21-29 Nm (16-21 ft. lbs.).
19. Install locking clip nut to transaxle eyelet for exhaust mounting bracket. Position catalytic converter assembly and loosely install one transaxle bolt to support exhaust.
20. Install four nuts to exhaust manifold. Tighten bolt at exhaust support to transaxle. Tighten nuts and bolt to 34-46 Nm (25-33 ft. lbs.).
21. Using a new gasket, position converter outlet to flex tube and install bolts and nuts. Tighten retainers to 34-46 Nm (25-33 ft. lbs.). Securely tighten nut at exhaust slotted bracket to front of transaxle.
22. Connect three HO2S connectors and locators at front and rear of sub-frame.
23. Install pinch bolts and nuts at lower ball joints. Tighten retainers to 68-92 Nm (57-67 ft. lbs.).
24. Connect left and right tie rod ends to front wheel knuckles. Install tie rod end nuts. Tighten nuts to 47-63 Nm (35-46 ft. lbs.), then continue to nearest cotter pin slot and install new cotter pins.
25. Connect left and right stabilizer bar links to strut assemblies. Install nuts and tighten to 30-40 Nm (23-29 ft. lbs.).
26. Position air deflector and securely install screws.
27. Install front wheel assemblies. Tighten wheel nuts to 115-142 Nm (85-104 ft. lbs.).
28. Lower vehicle.
29. Remove Adjustable Three Legged Engine Support 014-00750 or equivalent and Engine Lifting Brackets 303-050 (T70P-6000) when necessary.
30. Position coil pack bracket and install bolts at left rear cylinder head. Tighten bolts to 40-55 Nm (30-40 ft. lbs.). Connect number four, five, and six spark plug wires to coil.
31. Position ground wire and install bolt at right front cylinder head. Tighten bolt to 40-55 Nm (30-40 ft. lbs.).
32. Position manifold brace at right rear cylinder head and install bolt. Tighten the bolt to 40-55 Nm (30-40 ft. lbs.). Tighten upper bolt at intake manifold and tighten it to 8-12 Nm (71-106 inch lbs.).
33. Install three bolts and one stud retaining the transaxle to engine. Tighten retainers to 53-72 Nm (39-53 ft. lbs.). Position ground wire and starter harness locator to starter stud and securely install nut.
34. Install transaxle insulator-to-sub-frame nut. Tighten nut to 77-103 Nm (57-75 ft. lbs.).
35. Connect shift cable to shift lever and bracket. Securely install nut. Position speed control servo, install upper nut, and securely tighten lower nut.
36. Connect digital TR sensor, 10-pin harness, and HO2S connectors. Position harness and install harness locators at shift cable bracket and transaxle fill tube. Install bolt to harness locator at top of transaxle.
37. Place gearshift lever in OVERDRIVE position (D) position for vehicles equipped with a Transmission Control Switch [TCS]). Hang a weight of 1.4 kg (3 lbs.) on gearshift lever to verify lever is located firmly on OVERDRIVE position (D position on vehicles equipped with a TCS detent).
38. Loosen manual control lever-to-control cable retaining nut. Move transaxle manual control lever to OVERDRIVE position (D position on vehicles equipped with a TCS, second detent from most rearward position). Tighten retaining nut to 17-23 Nm (13-16 ft. lbs.).
39. Check operation of transaxle in each transmission range position. Make sure park mechanism and digital TR sensor are functioning properly.
40. Install the air filter, position the air cleaner, tighten the clamp at the throttle body and connect two clips.
41. Connect MAP sensor connector IAT sensor connector, and crankcase vent tubes to air cleaner assembly.
42. Install battery and hold down. Tighten retainer to 7-10 Nm (62-89 inch lbs.).
43. Connect positive and negative battery cables.
44. Fill transaxle with specified quantity and type of fluid.
45. Check operation of transaxle.
46. Check toe setting and adjust if necessary.