Installation

INSTALLATION








Special Tool(s)





1. NOTE: If the torque converter was not installed during assembly it must be installed now.

Using the special tool, install the torque converter.





2. NOTE: The torque converter hub must be fully seated into the transaxle pump drive gear.

Check the installation depth of the torque converter.
1. Lay a straightedge on the transaxle converter housing.
2. Check the clearance between the straight edge and the pilot hub.





3. Lubricate the torque converter pilot hub with Multi-Purpose Grease DOAZ-19584-AA meeting Ford specification ESB MlC93-B.





4. Install the special tool.





5. Position the transaxle with the PTU unit in place.





6. Remove the special tool.





7. Move the transaxle assembly toward the engine assembly and install the bolt.





8. Install the bolt.





9. Install the bolts.
10. Remove the transmission jack.





11. Install the fluid cooler line.





12. Install the OSS sensor.





13. Install the fluid cooler tube.
1. Install the fluid cooler tube.
2. Install the bolt.
3. Connect the output shaft speed (OSS) sensor.
4. Connect the turbine shaft speed (TSS) sensor (white connector).





14. Install four flexplate nuts.





15. Install the access cover.





16. Connect the main control cover tube.
17. Lower the vehicle.





18. Raise the transaxle enough to install the cross brace.
19. Raise and support the vehicle.





20. Install PTU unit and install one bolt.





21. Install the PTU bolts.





22. Install the cross brace.





23. Install the crossmember dampner.





24. Install the PTU bracket.
25. Install the RH exhaust manifold.
26. Install the rear driveshaft.





27. Install the exhaust pipe, and connect the exhaust pipe flange.





28. Connect the front flange.





29. Install the exhaust pipe.
1. Install the pipe, and install the bolts.
2. Install the rubber hanger.
3. Remove the special tool.





30. Reconnect the HO2S sensor wire to the oil pan bolt studs and connect the connector.





31. Install the cross brace.
32. Install the LH halfshaft assembly.

33. CAUTION: Align the mounting bracket studs and the intermediate shaft bearing bracket holes with the marks made during removal.

Install the RH halfshaft, intermediate shaft bearing, and intermediate shaft assembly.





34. Install the two splash shields.
35. Install both front wheels.
36. Lower the vehicle.





37. Lower the engine onto the RH engine mount.





38. Install the bolt for the RH engine mount.





39. Install the rear transaxle mount.





40. Install the transaxle mount assembly.





41. Install the bolts.





42. Remove the special tool.





43. Remove the special tool.





44. Remove the special tool.





45. Connect the electrical connectors to the valve cover.





46. Install the starter motor, and install two bolts.





47. Install the ground cable.





48. Install the starter motor harness connector.





49. Install the shift cable and bracket.





50. Install the wire harness clip to the shift cable bracket.





51. Connect the shift cable.





52. Connect the wire harness.





53. Install the wire harness bracket, and connect the transaxle harness connector.





54. Connect the H02S sensor.





55. Connect the two H02S sensors.





56. Connect the transmission range (TR) sensor.





57. NOTE: If not done during assembly, the digital TR sensor must be aligned.

Using the special tool, align the digital TR sensor.





58. Install the air cleaner assembly.





59. Install the intake tube and air cleaner cover.





60. Connect the breather tube and mass air flow (MAF) sensor.

61. NOTE: Before installing the battery tray, check the vent tube hose for any obstructions, kinks or incorrect routing position.

Install the battery and tray.

62. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 160 km (100 miles) or more to relearn the strategy.

Connect the battery cables.