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Section 456 (Automatic Transmission): Installation: Transaxle: Installation

WARNING: This page is about a different car, the 2002 Ford Focus. However, it is still accessible from the selected car via links, so may be relevant.

All vehicles 

NOTE: The location of the engine mountings and the engine support insulators are given looking from the automatic transaxle to the engine.
NOTE: Only install new self-locking nuts.
  1. Make sure that the torque converter hub is fully engaged in the oil pump drive gear.
    2. NOTE: Lubricate the torque converter pilot hub with multi-purpose grease.
  2. Check the installation depth of the torque converter.
    1. Lay a steel straightedge on the automatic transaxle flange.
    2. Check the installation depth between the transaxle flange and the torque converter centering spigot for the correct clearance.
      Fig 1: Checking Installation Depth Between Transaxle Flange And Torque Converter Centering Spigot
      G03433556Courtesy of FORD MOTOR CO.
  3. Remove the special tool.
    Fig 2: Removing Special Tool
    G03433557Courtesy of FORD MOTOR CO.
  4. Using a retaining strap, secure the transaxle on a transmission jack.
    5. NOTE: Make sure that the dowel pins are correctly installed in the engine block before installing the transaxle.
  5. Move the transaxle into position.
    6. NOTE: The location of the different length bolts.
    Fig 3: Installing Transaxle Left-Hand Flange Bolts
    G03433558Courtesy of FORD MOTOR CO.
  6. Install the transaxle left-hand flange bolts.
  7. Install the torque converter to the engine drive plate (four nuts) (2.0L SPI engine shown).
    • Rotate the crankshaft to access all the nuts.
      Fig 4: Installing Torque Converter To Engine Drive Plate
      G03433559Courtesy of FORD MOTOR CO.

      Vehicles with 2.0L SPI engine 

  8. Install the torque converter cover (if equipped).
    Fig 5: Installing Torque Converter Cover
    G03433560Courtesy of FORD MOTOR CO.

    Vehicles with 2.0L Zetec engine 

  9. Install the access plug.
    Fig 6: Installing Access Plug
    G03433561Courtesy of FORD MOTOR CO.

    All vehicles 

  10. Install the accessory drive belt cover.
    Fig 7: Installing Accessory Drive Belt Cover
    G03433562Courtesy of FORD MOTOR CO.
  11. Remove the retaining strap and the transmission jack from the transaxle.
  12. Install the transaxle right-hand flange bolt.
    Fig 8: Installing Transaxle Right-Hand Flange Bolt
    G03433563Courtesy of FORD MOTOR CO.
  13. Install the fluid filler pipe.
    Fig 9: Installing Fluid Filler Pipe
    G03433564Courtesy of FORD MOTOR CO.
  14. Install the starter motor lower retaining bolt.
    • Loosely install one upper bolt.
      Fig 10: Installing Starter Motor Lower Retaining Bolt
      G03433565Courtesy of FORD MOTOR CO.
  15. Lower the vehicle.
    16. NOTE: The location of the different length bolts.
    Fig 11: Installing Transaxle Upper Flange Bolts
    G03433566Courtesy of FORD MOTOR CO.
  16. Install the transaxle upper flange bolts.
  17. Install the engine rear mounting bracket.
    Fig 12: Installing Engine Rear Mounting Bracket
    G03433567Courtesy of FORD MOTOR CO.
  18. Using the special tool, raise the engine and transaxle assembly slightly.
  19. Install the engine rear mounting.
    Fig 13: Installing Engine Rear Mounting
    G03433568Courtesy of FORD MOTOR CO.
  20. Remove the special tools.
    Fig 14: Removing Special Tools
    G03433569Courtesy of FORD MOTOR CO.

    Vehicles with 2.0L SPI engine 

  21. Remove the left-hand side and right-hand side lifting brackets.
    Fig 15: Removing Lifting Brackets
    G03433570Courtesy of FORD MOTOR CO.

    All vehicles 

  22. Raise and support the vehicle.
    23. CAUTION: The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
    NOTE: Install new nuts and a new center bearing cap.
    Fig 16: Installing Nuts And Center Bearing Cap
    G03433571Courtesy of FORD MOTOR CO.
  23. Install the right-hand front drive halfshaft together with the intermediate shaft.
    24. CAUTION: The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
    NOTE: Install a new snap ring.
    Fig 17: Installing Snap Ring
    G03433572Courtesy of FORD MOTOR CO.
  24. Install the left-hand front drive halfshaft (shown with subframe removed for clarity).
  25. Install the lower suspension arm on both sides (left-hand side shown).
    1. Attach the suspension arm bolt joint.
    2. Install the bolt.
      Fig 18: Installing Bolt
      G03433573Courtesy of FORD MOTOR CO.
  26. Install the tie-rod end ball joint on both sides (left-hand side shown).
    Fig 19: Installing Tie-Rod End Ball Joint
    G03433574Courtesy of FORD MOTOR CO.
  27. Install the engine right-hand support insulator.
    Fig 20: Installing Engine Right-Hand Support Insulator
    G03433575Courtesy of FORD MOTOR CO.
  28. Connect the output speed (OSS) sensor electrical connector.
    Fig 21: Connecting Output Speed (OSS) Sensor Electrical Connector
    G03433576Courtesy of FORD MOTOR CO.
    29. CAUTION: Do not loosen the connecting fitting from the transaxle housing.
    NOTE: Location marks.
    Fig 22: Installing Fluid Cooler Pipes
    G03433577Courtesy of FORD MOTOR CO.
  29. Install the fluid cooler pipes.
  30. Install the front wheels and tires.

    Vehicles with 2.0L Zetec engine 

  31. Install the transaxle lower flange bolts.
    Fig 23: Installing Transaxle Lower Flange Bolts (2.0L Zetec Engine)
    G03433578Courtesy of FORD MOTOR CO.
  32. Lower the vehicle.

    Vehicles with 2.0L SPI engine 

  33. Install the transaxle lower flange bolts.
    Fig 24: Installing Transaxle Lower Flange Bolts (2.0L SPI Engine)
    G03433579Courtesy of FORD MOTOR CO.
  34. Install the catalytic converter.

    All vehicles 

  35. Install the fluid filler pipe and selector lever cable bracket.
    Fig 25: Installing Fluid Filler Pipe And Selector Lever Cable Bracket
    G03433580Courtesy of FORD MOTOR CO.
  36. Install the starter motor upper bolts.
    Fig 26: Installing Starter Motor Upper Bolts
    G03433581Courtesy of FORD MOTOR CO.
  37. Connect the electrical connectors and install the selector lever cable to the automatic transaxle selector lever.
    1. Transmission range (TR) sensor.
    2. Automatic transaxle.
      Fig 27: Installing Selector Lever Cable To Automatic Transaxle Selector Lever
      G03433582Courtesy of FORD MOTOR CO.
  38. Connect the turbine shaft speed (TSS) sensor electrical connector.
    Fig 28: Connecting Turbine Shaft Speed (TSS) Sensor Electrical Connector
    G03433583Courtesy of FORD MOTOR CO.
    39. NOTE: The resonator is plugged into the bracket.
    Fig 29: Installing Air Cleaner Intake Pipe With Resonator
    G03433584Courtesy of FORD MOTOR CO.
  39. Install the air cleaner intake pipe with the resonator.
    40. NOTE: Press the air cleaner housing into the rubber bushes.
  40. Install the air cleaner housing.
    1. Connect the mass air flow (MAF) sensor electrical connector.
    2. Connect the crankcase ventilation hose.
    3. Connect the air cleaner outlet hose.
      Fig 30: Connecting Crankcase Ventilation Hose
      G03433585Courtesy of FORD MOTOR CO.
  41. Tighten the strut and spring assembly top mount nuts on both sides (left-hand side shown).
    Fig 31: Tightening Strut And Spring Assembly Top Mount Nuts
    G03433586Courtesy of FORD MOTOR CO.
  42. Install the battery tray.
    1. Attach the wiring harness.
    2. Install in the bolts.
    3. Connect and secure the electrical connector.
      Fig 32: Connecting Electrical Connector
      G03433587Courtesy of FORD MOTOR CO.
  43. Install the battery.
  44. Check the routing of the vacuum hoses and wiring and secure them with cable ties.
  45. Fill the transaxle with automatic transmission fluid.
    46. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.
  46. Finishing operations:
    • Check fluid level after the road test and correct as necessary.
    • Check the transaxle for leaks (visual inspection).
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