Installation - Transaxle

Transaxle - Front Wheel Drive (FWD)

Special Tool(s):

Material:

Installation

CAUTION: MERCON (R), MERCON (R) V, MERCON (R) 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 transaxle will cause transaxle damage.

CAUTION: If a new transaxle or a mechatronic main control valve body assembly is installed, the transmission control module (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 transmission 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 transmission fluid cooler at this time.

1. If installing a new transaxle, install the transmission fluid level indicator, 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 transmission 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 in place and loosely install the bolt for the bracket.

14. Connect the heated oxygen sensor (HO2S) 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 HO2S 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 exhaust gas recirculation (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.).

42. Tighten the catalytic converter bolt to the bracket.
^ Tighten to 40 Nm (30 ft. lbs.).

43. Install the LH and RH halfshafts.
44. Position the exhaust crossover pipe and install 2 new bolts for the catalytic converter and connect the rubber hanger.
^ Tighten to 40 Nm (30 ft. lbs.).

45. Install 2 new nuts for the rear exhaust pipe.
^ Tighten to 40 Nm (30 ft. lbs.).

46. Install 2 new nuts for the front exhaust pipe.
^ Tighten to 40 Nm (30 ft. lbs.).

47. Install the 4 upper transaxle bolts.
^ Tighten to 40 Nm (30 ft. lbs.).

48. Install the bolt for the power steering line.
^ Tighten to 7 Nm (62 inch lbs.).

49. Connect the vapor tube to the canister purge valve.

50. Install the positive crankcase ventilation (PCV) hose.

51. Connect the vacuum hose to the throttle body.

52. Position the bracket for the power steering hose and install the bolt.
^ Tighten to 7 Nm (62 inch lbs.).

53. Install the transmission fluid cooler tube bracket to the transaxle.
^ Tighten to 10 Nm (89 inch lbs.).

54. Connect the ground wire.
^ Tighten to 12 Nm (9 ft. lbs.).

55. Connect the wire harness to the transaxle.

56. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.

Connect the transaxle bulkhead electrical connector.

57. Install the starter motor.
^ Tighten to 26 Nm (19 ft. lbs.).

58. Connect the 2 starter motor electrical connectors.
^ Tighten the larger nut to 12 Nm (9 ft. lbs.).
^ Tighten the smaller nut to 5 Nm (44 inch lbs.).

59. Install the electrical cover for the starter motor electrical connectors.

60. Clean the roll restrictor bolts using a wire brush and apply new threadlock to the threads.
61. Position the roll restrictor in place, install the bolts and connect the wire harness to the roll restrictor.
^ Tighten to 40 Nm (30 ft. lbs.).

62. Clean the 4 roll restrictor bracket bolts using a wire brush and apply new threadlock to the threads.
63. Install the roll restrictor bracket and 4 bolts.
^ Tighten to 40 Nm (30 ft. lbs.).

64. Connect the lower wire harness to the transaxle.

65. If equipped, install the auxiliary coolant flow pump assembly.
1 Tighten to 7 Nm (62 inch lbs.).
2 Install the electrical connector.

66. Connect the wire harness to the transaxle.

67. Install the shift cable bracket and bolts.
^ Tighten to 25 Nm (18 ft. lbs.).

68. Connect the electrical connector to the shift cable bracket.

69. Connect the shift cable end.

70. Clean the 4 roll restrictor brace bolts using a wire brush and apply new threadlock to the threads.
71. Position the roll restrictor brace in place and install the 4 bolts.
^ Tighten to 40 Nm (30 ft. lbs.).

72. Clean the upper roll restrictor bolt using a wire brush and apply new threadlock to the threads.
73. Install the upper roll restrictor bolt.
^ Tighten to 48 Nm (35 ft. lbs.).

74. Install the cowl panel grille.
75. Install the air cleaner and outlet tube.
76. Install the battery tray and the battery.
77. If required, fill the transaxle with clean continuously variable transaxle (CVT) transmission fluid. Use the transmission fluid level setting procedure to fill the transaxle.
78. 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.