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Engine - Automatic Transaxle

WARNING: This page is about a different car, the 2006 Mercury Milan and 2006 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL DESCRIPTION

G04680511Courtesy of FORD MOTOR CO.
 Heavy Duty Floor Crane
014-00071 or equivalent
G04680512Courtesy of FORD MOTOR CO.
 Spreader Bar
303-D089 (D93P-6001-A3) or equivalent
G04680513Courtesy of FORD MOTOR CO.
 Powertrain Lift
014-00765
G04680514Courtesy of FORD MOTOR CO.
 Universal Adapter Brackets
014-0001
Lifting Bracket Set, Engine
303-D095 (D94L-6001-A) or equivalent
ITEM SPECIFICATION

Item Specification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalent WSS-M2C930-A
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury.

    All vehicles 

  1. Using the engine crane and spreader bar, position the engine and transaxle together. Install the engine-to-transaxle bolts.
    • Tighten to 48 Nm (35 lb-ft).
  2. Using the engine crane and spreader bar, position the engine and transaxle onto the lift table.
    3. NOTE: Position a suitable block of wood under the transaxle.
    Fig 1: Locating Special Tools
    G04680515Courtesy of FORD MOTOR CO.
  3. Install the special tools onto the engine.
  4. Connect the transaxle pressure switch electrical connector.
    Fig 2: Locating Transaxle Pressure Switch Electrical Connector
    G04680516Courtesy of FORD MOTOR CO.
  5. Connect the output shaft speed (OSS) sensor electrical connector.
    Fig 3: Locating Output Shaft Speed (OSS) Sensor Electrical Connector
    G04680517Courtesy of FORD MOTOR CO.
  6. Connect the turbine shaft speed (TSS) sensor electrical connector.
    Fig 4: Locating Turbine Shaft Speed (TSS) Sensor Electrical Connector
    G04680518Courtesy of FORD MOTOR CO.
  7. Connect the transaxle control electrical connectors.
    Fig 5: Locating Transaxle Control Electrical Connectors
    G04680519Courtesy of FORD MOTOR CO.
  8. Connect the transmission range (TR) sensor and primary control solenoid electrical connectors.
    Fig 6: Locating Transmission Range (TR) Sensor And Primary Control Solenoid Electrical Connectors
    G04680520Courtesy of FORD MOTOR CO.
  9. Install the engine wiring harness bracket and nut.
    • Tighten to 20 Nm (15 lb-ft).
      Fig 7: Locating Engine Wiring Harness Bracket And Nut
      G04680521Courtesy of FORD MOTOR CO.
  10. Install the ground wire and bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 8: Locating Ground Wire And Bolt
      G04680522Courtesy of FORD MOTOR CO.
  11. Install new torque converter nuts.
    • Tighten to 35 Nm (26 lb-ft).
      Fig 9: Locating Torque Converter Nut
      G03897896Courtesy of FORD MOTOR CO.
  12. Install the starter and the 2 stud bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 10: Locating Starter And Stud Bolts
      G04680524Courtesy of FORD MOTOR CO.
  13. Connect the starter wires and install the 2 nuts.
    • Tighten the large nut to 12 Nm (9 lb-ft).
    • Tighten the small nut to 5 Nm (44 lb-in).
      Fig 11: Locating Starter Wire Nuts
      G04680525Courtesy of FORD MOTOR CO.
  14. Attach the 2 wiring harness retainers to the starter stud bolts.
  15. Raise the engine and transaxle into the vehicle.
  16. Install the 2 transaxle mount bolts.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 12: Locating Transaxle Mount Bolts
      G04680526Courtesy of FORD MOTOR CO.
  17. Install the engine mount bracket, 2 nuts and the bolt.
    • Tighten the nuts to 103 Nm (76 lb-ft).
    • Tighten the bolt to 115 Nm (85 lb-ft).
      Fig 13: Locating Engine Mount Bracket Nuts And Bolt
      G04680527Courtesy of FORD MOTOR CO.

    18. Vehicles with secondary air injection (AIR) 

  18. Install the AIR pump and the 3 bolts.
    • Tighten to 30 Nm (22 lb-ft).
      Fig 14: Locating AIR Pump Bolts
      G04680528Courtesy of FORD MOTOR CO.
  19. Connect the AIR pump electrical connector.
    Fig 15: Locating AIR Pump Electrical Connector
    G04680529Courtesy of FORD MOTOR CO.

    20. All vehicles 

  20. Install the 2 oil pan-to-bellhousing bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 16: Locating Oil Pan-To-Bellhousing Bolts
      G04680530Courtesy of FORD MOTOR CO.
  21. Install the bellhousing-to-oil pan bolt.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 17: Locating Bellhousing-To-Oil Pan Bolt
      G04680531Courtesy of FORD MOTOR CO.
  22. Install the RH halfshaft into the transaxle.
    Fig 18: Locating RH Halfshaft
    G04680532Courtesy of FORD MOTOR CO.
  23. Install the 2 RH halfshaft carrier bearing bracket bolts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 19: Locating RH Halfshaft Carrier Bearing Bracket Bolts
      G04680533Courtesy of FORD MOTOR CO.
    24. NOTE: Start one end of the circlip in the groove and work the circlip over the halfshaft and into the groove to prevent the circlip from overexpanding.
    Fig 20: Locating Halfshaft Circlip
    G03972275Courtesy of FORD MOTOR CO.
  24. Install a new circlip in the groove on the LH halfshaft.
  25. Install LH halfshaft into the transaxle.
  26. Connect the lower radiator hose and install the retaining clip.
    Fig 21: Identifying Lower Radiator Hose And Installing Retaining Clip
    G04680535Courtesy of FORD MOTOR CO.
  27. Install the radio frequency interference capacitor and the bolt on the engine mount bracket.
    • Tighten to 10 Nm (89 lb-in).
      Fig 22: Locating Radio Frequency Interference Capacitor And Bolt
      G04680536Courtesy of FORD MOTOR CO.
  28. Connect the A/C tube to the condenser and install the nut.
    • Tighten to 8 Nm (71 lb-in).
      Fig 23: Locating A/C Tube Nut
      G04680537Courtesy of FORD MOTOR CO.
  29. Connect the A/C tubes and install the 2 nuts.
    • Tighten to 8 Nm (71 lb-in).
      Fig 24: Locating A/C Tubes Nuts
      G04680538Courtesy of FORD MOTOR CO.
  30. Install the 2 A/C tube bracket bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 25: Locating A/C Tube Bracket Bolts
      G04680539Courtesy of FORD MOTOR CO.
  31. Attach the coolant vent hose retaining clip to the A/C tube.
    Fig 26: Locating Coolant Vent Hose Retaining Clip
    G04680540Courtesy of FORD MOTOR CO.
  32. Install the radio frequency interference capacitor, ground wire and the bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 27: Locating Radio Frequency Interference Capacitor, Ground Wire And Bolt
      G04680541Courtesy of FORD MOTOR CO.
  33. Connect the power steering cooler tube.
    Fig 28: Locating Power Steering Cooler Tube
    G04680542Courtesy of FORD MOTOR CO.
  34. Connect the transaxle cooler tubes.
    Fig 29: Locating Transaxle Cooler Tubes
    G04680543Courtesy of FORD MOTOR CO.
  35. Connect the transaxle control cable to the bracket.
    • Attach the control cable to the control lever.
      Fig 30: Locating Transaxle Control Cable
      G04680544Courtesy of FORD MOTOR CO.
  36. Connect the heater hose inline connector.
    Fig 31: Locating Heater Hose Inline Connector
    G04680545Courtesy of FORD MOTOR CO.
  37. If equipped, connect the block heater electrical connector and attach the harness retaining clips to the heater hose.
    Fig 32: Locating Block Heater Harness Retaining Clips
    G04680546Courtesy of FORD MOTOR CO.
  38. Connect the upper radiator and heater hoses to the coolant bypass.
    Fig 33: Locating Upper Radiator And Heater Hoses
    G04680547Courtesy of FORD MOTOR CO.
  39. Attach the evaporative emissions (EVAP) tube bundle retaining clip to the bracket.
    Fig 34: Locating Evaporative Emissions (EVAP) Tube Bundle Retaining Clip
    G04680548Courtesy of FORD MOTOR CO.
  40. Connect the EVAP tube to the intake manifold.
    Fig 35: Locating EVAP Tube
    G04680549Courtesy of FORD MOTOR CO.
  41. Insert the brake booster vacuum supply tube into the locking ring on the intake manifold.
    Fig 36: Locating Locking Ring And Brake Booster Vacuum Supply Tube
    G04680550Courtesy of FORD MOTOR CO.
  42. Connect the crankcase vent tube to the valve cover.
    Fig 37: Locating Crankcase Vent Tube
    G04680551Courtesy of FORD MOTOR CO.
  43. Connect the fuel supply tube to the fuel rail. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  44. Connect the powertrain control module (PCM) electrical connector and the pin-type retainer.
    Fig 38: Locating Powertrain Control Module (PCM) Electrical Connector And Pin-Type Retainer
    G04680552Courtesy of FORD MOTOR CO.
  45. Install the ground wire and the bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 39: Locating Ground Wire Bolt
      G04680553Courtesy of FORD MOTOR CO.
  46. Connect the 2 engine wiring harness electrical connectors.
    Fig 40: Locating Engine Wiring Harness Electrical Connectors
    G04680554Courtesy of FORD MOTOR CO.
  47. Connect the wire and install the nut on the battery cable.
    • Tighten to 10 Nm (89 lb-in).
      Fig 41: Locating Battery Cable And Nut
      G04680555Courtesy of FORD MOTOR CO.
  48. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  49. Install the engine air cleaner and air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING - 2.3L .
  50. Install the generator air inlet duct, bolt and the 2 nuts.
    • Tighten to 6 Nm (53 lb-in).
      Fig 42: Locating Generator Air Inlet Duct, Bolt And Nuts
      G04680556Courtesy of FORD MOTOR CO.
  51. Place the subframe assembly on the special tool and raise the subframe into the installed position.
    Fig 43: Identifying Special Tool
    G04680557Courtesy of FORD MOTOR CO.
    52. NOTE: LH shown, RH similar.
  52. Install the front subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
      Fig 44: Locating Front Subframe Nuts
      G04680558Courtesy of FORD MOTOR CO.
    53. NOTE: LH shown, RH similar.
    Fig 45: Locating Subframe Brackets Bolts
    G04680559Courtesy of FORD MOTOR CO.
  53. Position the subframe brackets and install the bolts finger-tight.
    54. NOTE: LH shown, RH similar.
  54. Install the subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
      Fig 46: Locating Subframe Nuts
      G04680560Courtesy of FORD MOTOR CO.
    55. NOTE: LH shown, RH similar.
    Fig 47: Locating Subframe Bracket-To-Body Bolts
    G04680561Courtesy of FORD MOTOR CO.
  55. Tighten the subframe bracket-to-body bolts to 103 Nm (76 lb-ft).
    56. NOTE: LH shown, RH similar.
  56. Install the through bolts into the lower control arms.
    • Tighten to 103 Nm (76 lb-ft).
      Fig 48: Locating Bolts
      G04680562Courtesy of FORD MOTOR CO.
    57. NOTE: LH shown, RH similar.
  57. Install the lower ball joint nuts.
    • Tighten to 200 Nm (148 lb-ft).
      Fig 49: Locating Lower Ball Joint Nuts
      G04680563Courtesy of FORD MOTOR CO.
    58. NOTE: LH shown, RH similar.
  58. Install the sway bar links and nuts to the struts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 50: Locating Sway Bar Links Nuts
      G04680564Courtesy of FORD MOTOR CO.
  59. Connect the power steering cooler tube.
    Fig 51: Locating Power Steering Cooler Tube
    G04680565Courtesy of FORD MOTOR CO.
    60. NOTE: LH shown, RH similar.
  60. Install tie-rod ends and nuts.
    • Tighten to 48 Nm (35 lb-ft).
    • Install the cotter pin.
      Fig 52: Locating Tie-Rod Ends Nuts And Cotter Pin
      G04680566Courtesy of FORD MOTOR CO.
  61. Install the LH splash shield and the 6 pin-type retainers (4 shown).
    Fig 53: Locating LH Splash Shield Pin-Type Retainers
    G04680567Courtesy of FORD MOTOR CO.
  62. Position the LH fender splash shield and install the 4 screws.
    Fig 54: Locating LH Fender Splash Shield Screws
    G04680568Courtesy of FORD MOTOR CO.
  63. Install the RH splash shield and the 6 pin-type retainers (4 shown).
    Fig 55: Locating Splash Shield Pin-Type Retainers
    G04684103Courtesy of FORD MOTOR CO.
  64. Position the RH fender splash shield and install the 4 screws.
    Fig 56: Locating RH Fender Splash Shield Screws
    G04684102Courtesy of FORD MOTOR CO.
  65. Install the engine roll restrictor bolt.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 57: Locating Engine Roll Restrictor Bolt
      G04680571Courtesy of FORD MOTOR CO.
  66. Route the power steering pressure (PSP) tube up into the engine compartment.
    Fig 58: Locating Power Steering Pressure (PSP) Tube
    G04680572Courtesy of FORD MOTOR CO.
  67. Slide the steering gear-to-dash seal onto the steering gear and engage the 4 retaining clips into the body.
    • From under the vehicle, verify that the seal is properly installed on the steering gear and the retaining clips are fully engaged into the dash.
      Fig 59: Locating Retaining Clips
      G04680573Courtesy of FORD MOTOR CO.
  68. Install the oil filter element. For additional information, refer to ENGINE LUBRICATION COMPONENTS - EXPLODED VIEW  and OIL FILTER ELEMENT .
  69. Install the exhaust flexible pipe. For additional information, refer to EXHAUST SYSTEM .
  70. If equipped, install the underbody cover and the 7 screws.
    Fig 60: Locating Underbody Cover Screws
    G04680574Courtesy of FORD MOTOR CO.
  71. Connect the PSP tube to the power steering pump and install the bolt.
    • Tighten to 35 Nm (26 lb-ft).
      Fig 61: Locating PSP Tube To Power Steering Pump Bolt
      G04680575Courtesy of FORD MOTOR CO.
    72. NOTE: Align the index marks made during removal.
  72. Install the steering intermediate shaft onto the steering gear and install the bolt.
    • Tighten to 23 Nm (17 lb-ft).
      Fig 62: Locating Steering Intermediate Shaft Bolt
      G04680576Courtesy of FORD MOTOR CO.
  73. Install the steering joint cover and the 2 nuts.
    Fig 63: Locating Steering Joint Cover And Nuts
    G04680577Courtesy of FORD MOTOR CO.
  74. Fill the engine with clean engine oil.
  75. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  76. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING .
  77. Fill the power steering system. For additional information, refer to STEERING SYSTEM-GENERAL INFORMATION .
  78. Recharge the air conditioning system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS
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