Part 1 of 2

Transaxle - All Wheel Drive (AWD)

Special Tool(s):

Special Tool(s):

Material:

Installation (Steps 1-41)

CAUTION: MERCON, MERCON V, MERCON SP, Motorcraft Premium Automatic Transmission Fluid and Motorcraft Continuously Variable Chain Type Transmission Fluid are not interchangeable transmission fluids. The use of any fluid other than what is recommended for this transmission will cause transmission damage.

CAUTION: If a new transaxle or a mechatronic main control valve body assembly is installed, the TCM will need to be reflashed to the latest level calibration available. If the TCM is not reflashed, the wrench light on the dash may illuminate and internal transaxle damage may occur.

NOTE: If the transaxle was overhauled or if installing a new transaxle and the transmission fluid cooler tubes have not been flushed, flush the fluid cooler tubes at this time.

If the transaxle was overhauled or if installing a new transaxle and a new transmission fluid cooler has not been installed, install a new fluid cooler at this time.





1. If installing a new transaxle, install the fluid level indicator and tube and the bolt.
^ Tighten to 10 Nm (89 inch lbs.).





2. If installing a new transaxle, install the transaxle insulator using new retainers.
3. If removed, clean the rear transaxle mount bolts using a wire brush and apply new threadlock to the threads.





4. If installing a new transaxle, install the rear transaxle support insulator.
^ Tighten to 55 Nm (41 ft. lbs.).





5. Prior to installing the original or a new transaxle, apply multi-purpose grease to the torque converter pilot hub.
6. Position the transaxle to the back of the engine.





7. Install the 3 transaxle-to-engine retaining bolts.
^ Tighten to 40 Nm (30 ft. lbs.).





8. Install 4 new transmission fluid cooler tube seals.

9. CAUTION: Make sure that when installing the fluid cooler tubes they are installed straight, or damage to the tubes will occur.





Connect the transmission fluid cooler tubes to the transaxle.
^ Tighten to 10 Nm (89 inch lbs.).





10. Position the transmission fluid cooler tubes in place and install the bolts.
^ Tighten to 10 Nm (89 inch lbs.).





11. Install 4 new torque converter retaining nuts.
^ Tighten to 36 Nm (27 ft. lbs.).





12. Install the lower rubber access plug and install the retaining pin.





13. Position the catalytic converter is place and loosely install the bolt for the bracket.





14. Connect the H02S electrical connector.





15. Using a suitable powertrain lift, position the subframe in place and install the 4 bolts.
^ Tighten to 90 Nm (66 ft. lbs.).





16. Install the 2 bolts for the LH rear subframe mount.
^ Tighten to 48 Nm (35 ft. lbs.).





17. Install the 2 bolts for the RH rear subframe mount.
^ Tighten to 48 Nm (35 ft. lbs.).





18. Install the 2 bolts for the rear transaxle mount.
^ Tighten to 90 Nm (66 ft. lbs.).





19. Install the nut for the rear motor mount.
^ Tighten to 70 Nm (52 ft. lbs.).





20. Install the 2 bolts for the lower stabilizer mount.
^ Tighten to 70 Nm (52 ft. lbs.).





21. Install the nut for the front motor mount.
^ Tighten to 70 Nm (52 ft. lbs.).





22. Position the splash shield in place and install the 3 pushpins.





23. Connect the H02S electrical connector to the subframe.





24. Position the power steering rack in place. Install the bolts and nuts.
^ Tighten to 133 Nm (98 ft. lbs.).





25. Position the power steering line in place and install the 4 bolts.
^ Tighten to 7 Nm (62 inch lbs.).





26. Connect the wire harness to the LH front subframe.





27. Position the lower radiator hose in place and connect the retainers.





28. Install the LH and RH stabilizer bar link into the struts and install new nuts.
^ Tighten to 55 Nm (41 ft. lbs.).





29. Remove the special tool from the lifting hook near the EGR valve.





30. Remove the special tools from the RH (rear) cylinder head.





31. Remove the special tools from the LH (front) cylinder head.





32. Remove the special tools.





33. Install new bolts for the catalytic converter.
^ Tighten to 40 Nm (30 ft. lbs.).





34. Remove the upper half of the lifting hook.





35. Remove the lower half of the lifting hook.





36. Install the transaxle-to-engine bolt.
^ Tighten to 40 Nm (30 ft. lbs.).





37. Connect the knock sensor wire harness to the transaxle.





38. Install the knock sensor.
^ Tighten to 10 Nm (89 inch lbs.).





39. Install the heat shield over the knock sensor.





40. If equipped, connect the engine block heater.





41. Position the power steering hose in place and install the bolt.
^ Tighten to 7 Nm (62 inch lbs.).