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Section 2032 (Manual Transmission): Installation: Transaxle

WARNING: This page is about a different car, the 2007 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
Special Tools

Illustration Tool Name Tool Number
GF0000161
 3-Bar Engine Support Kit 303-F072 or equivalent
Material

Item Specification
Premium Long-Life Grease
XG-1-C or XG-1-K (US); CXG-1-C (Canada)		 ESA-M1C75-B
High Performance DOT 3 Motor Vehicle Brake Fluid
PM-1-C (US); CPM-1-C (Canada)		 WSS-M6C62-A
  1. Do not lubricate the splines on the input shaft.
    2. WARNING: Secure the transaxle to the transmission jack with a safety chain. Failure to follow these instructions may result in personal injury.
  2. Raise and position the transaxle.
  3. Install the 5 short transaxle-to-engine bolts.
    • Tighten to 47 Nm (35 lb-ft).
  4. Install the long transaxle-to-engine bolt.
    • Tighten to 47 Nm (35 lb-ft).
  5. Install the exhaust outlet pipe. For additional information, refer to EXHAUST SYSTEM article.
  6. Install the transaxle front support insulator bracket.
    1. Install the transaxle front support insulator bracket.
    2. Install the 3 bolts.
      • Tighten to 48 Nm (35 lb-ft).
    3. Install the transaxle front support insulator.
    4. Install the through-bolt.
      • Tighten to 115 Nm (85 lb-ft).
    7. Fig 1: Transaxle Front Support Insulator & Bolts
    GF0025423Courtesy of FORD MOTOR CO.
    CAUTION: Make sure to use the seal protector when installing the RH intermediate shaft and the LH halfshaft. Failure to use the seal protector may result in transmission oil leaks.
  7. Install the RH intermediate axleshaft and the LH halfshaft. For additional information, refer to FRONT DRIVE HALFSHAFTS article.
  8. If equipped, install the transfer case. For additional information, refer to TRANSFER CASE - POWER TRANSFER UNIT (PTU) article.
  9. Install the starter motor assembly. For additional information, refer to STARTING SYSTEM article.
  10. Install the LH side splash shield.
    1. Position the LH splash shield.
    2. Install the 2 screws.
    11. Fig 2: Left Side Splash Shield
    GF0025424Courtesy of FORD MOTOR CO.
  11. Install the 3 LH splash shield screws.
    12. Fig 3: Left Side Splash Shield Screws
    GF0025342Courtesy of FORD MOTOR CO.
  12. Install the front-to-aft crossmember.
    1. Position the crossmember.
    2. Install the 2 bolts and nut.
      • Tighten the bolts to 90 Nm (66 lb-ft).
      • Tighten the new nut to 175 Nm (129 lb-ft).
    3. Install the splash shield screw.
    4. Install the 2 transaxle front support insulator bolts.
      • Tighten to 90 Nm (66 lb-ft).
    13. Fig 4: Crossmember & Fasteners
    GF0025425Courtesy of FORD MOTOR CO.
  13. Install the crossmember.
    1. Position the crossmember.
    2. Install the bolts.
      • Tighten to 115 Nm (85 lb-ft).
    14. Fig 5: Crossmember & Bolts
    GF0025426Courtesy of FORD MOTOR CO.
  14. Install the 3 upper transaxle-to-engine bolts. Tighten the bolts to 47 Nm (35 lb-ft).
    15. Fig 6: 3 Upper Transaxle-To-Engine Bolts
    GF0025340Courtesy of FORD MOTOR CO.
  15. Install the transaxle rear support insulator.
    1. Position the transaxle rear support insulator.
    2. Install the through-bolt.
      • Tighten to 115 Nm (85 lb-ft).
    3. Install the nuts.
      • Tighten to 80 Nm (59 lb-ft).
    4. Install the bolt.
      • Tighten to 80 Nm (59 lb-ft).
    16. Fig 7: Transaxle Rear Support Insulator & Fasteners
    GF0025427Courtesy of FORD MOTOR CO.
  16. Install the LH transaxle support insulator bracket.
    1. Position the LH transaxle support insulator bracket.
    2. Install the through-bolt.
      • Tighten to 103 Nm (76 lb-ft).
    3. Install the 3 nuts.
      • Tighten to 40 Nm (30 lb-ft).
    17. Fig 8: Left Transaxle Support Insulator Bracket & Fasteners
    GF0025428Courtesy of FORD MOTOR CO.
  17. Install the shift cable bracket.
    1. Position the shift cable bracket.
    2. Install the 3 bolts.
      • Tighten to 22 Nm (16 lb-ft).
    18. Fig 9: Shift Cable Bracket & Bolts
    GF0025429Courtesy of FORD MOTOR CO.
  18. Connect the clutch hydraulic line.
    1. Position the clutch hydraulic line.
    2. Connect the clutch hydraulic line from the clutch slave cylinder.
    3. Install the clutch hydraulic line bracket-to-transaxle bolt.
      • Tighten to 2.5 Nm (22 lb-in).
    19. Fig 10: Clutch Hydraulic Line & Components
    GF0025430Courtesy of FORD MOTOR CO.
  19. Connect the shift cables.
    20. Fig 11: Shift Cables
    GF0025334Courtesy of FORD MOTOR CO.
  20. Connect the reverse switch and vehicle speed sensor (VSS) connectors.
    21. Fig 12: Reverse Switch & Vehicle Speed Sensor (VSS) Connectors
    GF0025333Courtesy of FORD MOTOR CO.
  21. Install the wiring harness bracket nuts.
    • Tighten to 12 Nm (9 lb-ft).
    22. Fig 13: Wiring Harness Bracket Nuts
    GF0025332Courtesy of FORD MOTOR CO.
  22. Install the air cleaner outlet tube.
    1. Install the air cleaner outlet tube.
    2. Tighten the clamp.
    3. Connect the emission management tube and hose.
    23. Fig 14: Air Cleaner Outlet Tube
    GF0025431Courtesy of FORD MOTOR CO.
  23. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
  24. Install the air cleaner assembly. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - 2.3L article.
  25. Fill the transaxle fluid. For additional information, refer to Transaxle Draining and Filling .
    26. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in personal injury.
    CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, wash it immediately with cold water.
  26. Fill and bleed the clutch. For additional information, refer to MANUAL TRANSAXLE/TRANSMISSION AND CLUTCH - GENERAL INFORMATION article.
  27. Adjust the shift cables.
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