Part 1
Transaxle - 3.5LSpecial Tool(s) (Part 1):
Special Tool(s) (Part 2):
Material:
Installation (Steps 1-27)
CAUTION: MERCON(R) MERCON(R)V, MERCON(R)SP, Motorcraft Premium Automatic Transmission Fluid and Motorcraft Continuously Variable Chain Type Transmission Fluid are not interchangeable transmission fluids. The use of any transmission fluid other than what is recommended for this transaxle will cause transaxle damage.
NOTE: If the transaxle was overhauled, or if installing a new transaxle and the transmission fluid cooler has not been flushed, flush the transmission fluid cooler at this time. For additional information, refer to Transmission Fluid Cooler Backflushing and Cleaning.
All vehicles
1. Prior to installing the transaxle, apply multi-purpose grease to the torque converter pilot hub.
2. Position the transaxle to the back of the engine.
3. Install the 7 transaxle-to-engine bolts.
^ Tighten to 48 Nm (35 lb-ft).
4. Connect the transmission fluid cooler hoses to the transaxle.
5. Install 4 new torque converter nuts.
^ Tighten to 36 Nm (27 lb-ft).
6. Position the inspection cover in place and install the 2 fasteners.
All wheel drive (AWD) vehicles
7. Position the power transfer unit (PTU) in place and install the 5 bolts.
^ Tighten to 90 Nm (66 lb-ft).
8. Using the special tools, install a new intermediate shaft seal.
9. NOTE: Do not overheat (melt) the seal deflector. If the deflector is damaged, a new one must be used.
Using a suitable heat gun, heat the new seal deflector. Concentrate the heat across the back of the deflector near the white colored tabs. Install the seal deflector immediately after heating.
^ If necessary, use special tools 308-430 and 308-431 to seat the seal deflector. Make sure the deflector is fully seated and there are no cracks on the face or inner diameter white colored tab.
^ For an alternate method to heat the seal deflector, place the deflector in boiling water for 3 to 5 minutes. Dry off deflector and install.
^ Make sure the deflector is completely seated all the way around.
10. Position the PTU support bracket in place and install the 5 bolts.
^ Tighten to 70 Nm (52 lb-ft).
11. Position the RH catalytic converter in place and install the 4 nuts.
^ Tighten to 40 Nm (30 lb-ft).
12. Install the 2 catalytic converter bracket bolts.
^ Tighten to 20 Nm (15 lb-ft).
13. Connect the RH catalyst monitor electrical connector.
14. Position the driveshaft in place, align the index marks made during removal and install the bolts.
^ Tighten to 70 Nm (52 lb-ft).
15. Position the RH halfshaft in the transaxle and in the wheel hub and install the 2 bolts.
^ Tighten to 23 Nm (17 lb-ft).
Front wheel drive (FWD) vehicles
16. Install the RH halfshaft in the transaxle and install the 3 bolts.
^ Tighten to 55 Nm (41 lb-ft).
17. Install the catalytic converter support bracket and install the 2 nuts.
^ Tighten to 23 Nm (17 lb-ft).
18. Install the 2 catalytic converter bracket bolts.
^ Tighten to 20 Nm (15 lb-ft).
All vehicles
19. NOTE: LH shown, RH similar.
Position the subframe in place and install the 2 front subframe nuts.
^ Tighten to 150 Nm (111 lb-ft).
20. Position the subframe support brackets in place and loosely install the bolts.
21. Install the rear subframe nuts.
^ Tighten to 150 Nm (111 lb-ft).
22. Tighten the subframe support bracket bolts.
^ Tighten to 103 Nm (76 lb-ft).
23. Position the steering gear in place and install the 3 bolts.
^ Tighten to 107 Nm (79 lb-ft).
24. Position the power steering cooler tube in place and install the bolts.
^ Tighten to 9 Nm (80 lb-in).
25. Install the 2 roll restrictor bracket bolts.
^ Tighten to 90 Nm (66 lb-ft).
26. Install the bolt connecting the RH damper fork to the lower control arm.
^ Tighten to 103 Nm (76 lb-ft).
27. Position the lower control arms in the knuckle and install the nuts.
^ Tighten to 200 Nm (148 lb-ft).
