Installation

Special Tools:

1. NOTE: Use new self-locking nuts.
General instructions:
- The following instructions apply to the CD4E automatic transaxle with 2.5L engine.
- The location of engine mountings and roll restrictor are described looking from the automatic transaxle to the engine.

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

Check the installation depth of the torque converter.





1 Lay a steel straightedge on the automatic transaxle flange.
2 Check the installation depth between the transaxle flange and the torque converter centering spigot for the correct clearance.

- Installation depth for 2.0L Zetec-Engine = 12 mm (0.47 inch).
- Installation depth for 2.5L = 2 mm (0.08 inch).
- Apply a thin layer of grease meeting Ford Specification ESD-M1C220-A or equivalent to the centering spigot bore on the torque converter.

3. 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 flexible holes before any transaxle to engine bolts are installed.





Install special tool.





4. 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.

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





Install the front bellhousing bolts.





6. Install the lower bellhousing bolts.





7. Install the four torque converter nuts.
- Rotate the torque converter to gain access to remaining nuts.
- Install torque converter rubber.

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

8. NOTE: Do not damage the oil seal.





Install the right-hand halfshaft and intermediate shaft.





9. Install a new snap-ring.

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

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





Install the left-hand halfshaft.

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





Position and install the lower transaxle cooling tube.

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





Position and install the upper transaxle cooling tube.

13. NOTE: Do not tighten the bolt.





Install the right-hand roll restrictor center bolt.

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

NOTE: Do not tighten the bolts.





Install the sub-frame.





15. Install the steering intermediate shaft.





16. Install the transaxle cooler line brackets.
- Position the suction accumulator (A/C), If eq1upped.





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





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





19. Install the steering gear heat shield.

20. 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.

21. Replace the front roll restrictor with the special tool.





1 Install special tool.
2 Install the bolts.
3 Install the through bolt.

22. Lower the vehicle.





23. Tighten the rear transaxle support bracket nuts.





24. Tighten the front engine support insulator bracket nuts.
25. Raise and support the vehicle





26. Tighten the right-hand roll restrictor center bolt.
27. Replace the special tool with the left-hand engine support isolator.





1 Install the center bolt.
2 Install the bolts.





28. Install the control arm.

29. CAUTION: Over bending of the flexible pipe may cause damage resulting in failure.





Install the flexible tube and the rear TWC.
- Install the gaskets.
- Hang up the TWC into the rubber hangers.





30. Install the flexible tube and the TWC (continuation).
- Install the gaskets.





31. Install the cable ties.

Vehicles with air conditioning





32. Install the suction accumulator (A/C) bolts.

All Vehicles





33. Install the bumper bracket.





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





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





36. Install the radiator splash shield.
- Install the bolts and clips.

37. Lower the vehicle.





38. Install both front wheels (right hand side shown).
39. Install the selector cable.





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

40. NOTE: Install harness from transaxle.





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





41. Connect the plug from the Turbine Shaft Speed Sensor (TSS) (shown from below).
- Clip the cable.





42. Connect the OSS sensor electrical connector.

43. NOTE: Ground cable.





Install the upper bellhousing bolts (four bolts).





44. Remove the special tools.





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





46. Check that the selector lever position indicator corresponds with the transaxle operation.
- Parking lock in selector lever position P, reverse ,-ear in selector lever position R and forward in selector lever position D.

47. If the selector lever position indicator does not correspond with the transaxle operation in all settings:
- Raise the vehicle and disconnect the head shield (four clips).

48. NOTE: The mark line up in position dither selector lever has its own detent mechanism. Holding the selector lever is not necessary.

Move the selector lever to position D.





1 Prevent the selector cable from turning
2 Disconnect the selector cable adjusting cap.
3 Move the selector lever to position D.

49. Adjust the selector lever scale position.
- Remove the selector lever nuts.

50. NOTE: The selector lever has its own detent mechanism. Holding the selector lever is not necessary.

Slide the whole selector assembly forwards or backwards until the reading on the scale and the position of the selector lever indicator correspond.





51. Tighten the selector lever nuts.

52. NOTE: The selector lever has its own detent mechanism. Holding the selector lever is not necessary.





Move the autocratic transaxle selector lever to position D.
53. Lock the selector cable.





1 Prevent the selector cable from turning.
2 Lock the selector cable adjustment cap.

- Fit the heat shield.





54. Install the water pump pulley cover.
- Attach the engine coolant hose and install the bolts.

55. 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

56. NOTE: Use an Allen key to stop the piston rod from turning.





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





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





58. Remove the radiator supports.


See TSB 06-14-4





59. Fill up the transaxle with MERCON (R) multipurpose automatic transmission fluid. MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4.
60. 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.
61. Install the battery tray.
62. Fill and bleed the power steering system.