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Section 357 (Automatic Transaxle/Transmission): Installation: Transaxle: Installation

WARNING: This page is about a different car, the 2002 Mercury Villager. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: Prior to the installation of the transaxle, the fluid cooler lines and the fluid cooler will need to be cleaned. Transaxle failure could occur if not cleaned.
    Fig 1: Positioning Transaxle On Suitable Jack
    G03412690Courtesy of FORD MOTOR CO.
  1. Position and secure the transaxle on a suitable jack.
    2. CAUTION: Prior to the installation of the transaxle, the torque converter pilot hub must be properly lubricated or damage to the torque converter or the engine crankshaft may occur.
  2. Lubricate the torque converter pilot hub using Ford Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specification ESB-M1C93-B.
  3. Position the separator plate on the engine alignment pins.
    4. CAUTION: The torque converter must remain at the correct installation depth throughout the installation procedure.
    NOTE: The torque converter must be aligned with the flywheel holes before any transaxle to engine bolts are installed.
  4. Lift the transaxle into position.
  5. Install the transaxle insulator support.
    1. Position the insulator support.
    2. Install the support insulator bolts.
    3. Install the through bolt.
      Fig 2: Installing Transaxle Insulator Support
      G03412691Courtesy of FORD MOTOR CO.
  6. Install the transaxle support insulator bracket nuts.
    Fig 3: Installing Transaxle Support Insulator Bracket Nuts
    G03412692Courtesy of FORD MOTOR CO.
  7. Install the LH engine to transaxle bolt.
    Fig 4: Installing LH Engine To Transaxle Bolt
    G03412693Courtesy of FORD MOTOR CO.
  8. Install the RH engine to transaxle bolt.
    Fig 5: Installing RH Engine To Transaxle Bolt
    G03412694Courtesy of FORD MOTOR CO.
  9. Remove the jack.
    10. NOTE: Rotate the engine to access the 4 torque converter bolts.
    Fig 6: Installing Torque Converter Bolts
    G03412695Courtesy of FORD MOTOR CO.
  10. Install the torque converter bolts.
  11. Install the transaxle inspection cover.
    1. Position the cover.
    2. Install the lower front transaxle bell housing bolts.
      Fig 7: Installing Lower Front Transaxle Bell Housing Bolts
      G03412696Courtesy of FORD MOTOR CO.
  12. Install the lower rear bell housing bolts.
    Fig 8: Installing Lower Rear Bell Housing Bolts
    G03412697Courtesy of FORD MOTOR CO.
  13. Tighten the engine/transaxle brace bolts.
    Fig 9: Tightening Engine/Transaxle Brace Bolts (1 Of 2)
    G03412698Courtesy of FORD MOTOR CO.
  14. Tighten the engine/transaxle brace bolts.
    Fig 10: Tightening Engine/Transaxle Brace Bolts (2 Of 2)
    G03412699Courtesy of FORD MOTOR CO.
  15. Connect the vehicle speed sensor.
    Fig 11: Connecting Vehicle Speed Sensor
    G03412700Courtesy of FORD MOTOR CO.
  16. Connect the transaxle ground strap.
    Fig 12: Connecting Transaxle Ground Strap
    G03412701Courtesy of FORD MOTOR CO.
  17. Connect the shifter cable.
    1. Clip the cable into the bracket.
    2. Install the nut.
      Fig 13: Connecting Shifter Cable
      G03412702Courtesy of FORD MOTOR CO.
  18. Connect the transaxle fluid lines.
    Fig 14: Connecting Transaxle Fluid Lines
    G03412703Courtesy of FORD MOTOR CO.
  19. Connect the transaxle range sensor.
    Fig 15: Connecting Transaxle Range Sensor
    G03412704Courtesy of FORD MOTOR CO.
  20. Install the engine splash shield.
  21. Lower the vehicle.
  22. Install the upper engine to transaxle bolts.
    Fig 16: Installing Upper Engine To Transaxle Bolts
    G03412705Courtesy of FORD MOTOR CO.
  23. Connect the transaxle harness.
    1. Clip the harness onto the bracket.
    2. Connect the transaxle harness connector.
      Fig 17: Connecting Transaxle Harness
      G03412706Courtesy of FORD MOTOR CO.
  24. Install the transaxle fill tube.
    1. Position the fill tube.
    2. Install the fill tube nuts.
    3. Install the ground strap nut.
      Fig 18: Installing Transaxle Fill Tube
      G03412707Courtesy of FORD MOTOR CO.
  25. Install the crankshaft position (CKP) sensor.
    Fig 19: Installing Crankshaft Position (CKP) Sensor
    G03412708Courtesy of FORD MOTOR CO.
  26. Install the CKP sensor heat shield.
    1. Position the heat shield.
    2. Install the nut.
      Fig 20: Installing Nut
      G03412709Courtesy of FORD MOTOR CO.
  27. Connect the transaxle electrical connectors.
    1. Connect the CKP sensor connector.
    2. Connect the transaxle harness connector.
      Fig 21: Connecting Transaxle Electrical Connectors
      G03412710Courtesy of FORD MOTOR CO.
  28. Install the starter motor. Refer to STARTERS .
  29. Install the halfshafts. Refer to AXLE SHAFTS .
    30. NOTE: Add the amount that was measured during fluid draining.
  30. Fill the transaxle with Motorcraft MERCON® Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON®.
  31. Run the engine until the transaxle fluid reaches 66°-77° C (151°-171°F).
  32. While the engine is idling, apply the service brake and shift from PARK (P) to MANUAL LOW (1) and back, stopping in every gear.
  33. With the vehicle in PARK, check the transaxle fluid level and add as necessary.
    1. Use the lower temperature scale when the transaxle fluid is between 30°-50°C (86°-122°F).
    2. Use the upper temperature scale when the transaxle fluid is between 66°-77°C (151°-171°F).
      Fig 22: Identifying Fluid Level Temperature Scale
      G03412711Courtesy of FORD MOTOR CO.
  34. Add Motorcraft MERCON® Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON® if necessary.
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