Installation
1. Place the transaxle on Rotunda Hi-Lift Jack 014-00210 or equivalent.
2. Apply a thin coating of Premium Long-Life Grease XG-1-C or XG-1-K, or equivalent meeting Ford specification ESA-M1C75-B to the spline of the input shaft.
3. Lift the transaxle into the engine compartment and align it with the engine.
4. Mount the transaxle to the engine and hand tighten the lower transaxle-to-engine bolts.
5. Remove the transmission jack from the transaxle.
6. Install the two nuts, one bolt, and the through bolt into the LH transaxle support insulator. Tighten the two LH transaxle support insulator nuts to 44-60 Nm (32-44 ft lbs.) and the LH transaxle support insulator through bolt to 86-116 Nm (63-86 ft. lbs.).
7. Install the rear transaxle support insulator and the three bolts. Tighten the rear transaxle support bracket bolts to 67-93 Nm (50-68 ft. lbs.).
8. Install the control rod and the control rod to support bar stud nut. Tighten the control rod to support bar stud nut to 38-51 Nm (28-38 ft. lbs.).
9. Install the transmission selector shift rod adjustment sleeve. Tighten the transmission selector shift rod adjustment sleeve nut to 19-25 Nm (14-18 ft. lbs.).
10. Install the transmission support crossmember. Tighten the rear engine support bolts and nuts (B) to 67-93 Nm (50-68 ft. lbs.), rear engine support nuts (A) to 75-104 Nm (55-77 ft. lbs.) and rear engine support nuts (C) to 44-60 Nm (32-44 ft. lbs.).
11. Remove the transaxle plug from the RH side of the transaxle.
12. Install the RH front wheel driveshaft and joint into the flywheel housing.
13. Install the RH front wheel driveshaft and joint into the front wheel knuckle.
NOTE: It may be necessary to pull out on the lower edge of the front disc brake rotor to gain clearance for inserting the front wheel driveshaft and joint into the wheel hub.
14. Pry the front suspension lower arm down to engage the lower ball joint.
15. Install the RH lower ball joint bolt and nut. Tighten the RH lower ball joint nut to 35-56 Nm (26-41 ft. lbs.).
16. On vehicles equipped with ABS, install the front anti-lock sensor and bracket harness mounting nuts. Tighten the front anti-lock sensor and bracket harness nuts to 8-10 Nm (71-88 inch lbs.).
17. On vehicles equipped with ABS, install the front anti-lock sensor and bracket harness clips.
18. Install the three front axle bearing bracket bolts. Tighten the front axle bearing bracket bolts in the order shown to 43-61 Nm (32-45 ft. lbs.).
19. Remove Transaxle Plugs T88C-7025-AH from the LH side of the transaxle case.
20. Install the LH front wheel driveshaft and joint into the transaxle case.
21. Install the LH front wheel driveshaft and joint into the front wheel knuckle.
NOTE: It may be necessary to pull out on the lower edge of the front disc brake rotor to gain clearance when inserting the front wheel driveshaft and joint into the wheel hub.
22. Pry the front suspension lower arm down to engage the lower ball joint.
23. Install the LH lower ball joint bolt and nut. Tighten the lower ball joint nut to 35-56 Nm (26-41 ft lbs.).
24. On vehicles equipped with ABS, install the LH front anti-lock sensor and bracket harness mounting nuts. Tighten the front anti-lock sensor and bracket harness nuts to 8-10 Nm (71-88 inch lbs.).
25. On vehicles equipped with ABS, install the front wheel anti-lock sensor and bracket harness clips.
26. Align the exhaust inlet pipe and install three new exhaust inlet pipe-to-exhaust manifold nuts. Tighten the exhaust inlet pipe-to-exhaust manifold nuts to 40-55 Nm (30-41 ft. lbs.).
27. Connect the heated oxygen sensor (HO2S) electrical connectors.
28. Align the crossmember and install the six crossmember bolts. Tighten the crossmember bolts to 94-131 Nm (69-96 ft. lbs.).
29. Install two new front axle wheel hub retainers and tighten the front wheel driveshaft and joint nuts to 235-319 Nm (174-235 ft. lbs.).
Fig. 7 Staking axle nut:
30. Stake the new front wheel driveshaft and joint nuts in place.
NOTE: Do not use a sharp tool to stake the front wheel driveshaft and joint nuts.
31. Install the wheel and tire assemblies. Tighten the lug nuts to 88-118 Nm (65-87 ft. lbs.).
32. Install a new washer and the transaxle drain-plug. Tighten the transaxle drain-plug to 40-58 Nm (29-43 ft lbs.).
NOTE: To ensure that the transaxle does not leak, clean the transaxle drain-plug and around the transaxle drain orifice.
33. Install the starter motor.
34. Tighten the lower starter motor bolt to 35-51 Nm (28-38 ft. lbs.).
35. Connect the B-terminal wire and install the B-terminal wire nut.
36. Connect the S-terminal wire.
37. Install the front fender splash shields.
38. Tighten the lower splash shield bolts to 8-10 Nm (71-88 inch lbs.).
39. Install the three lower transaxle-to-engine bolts. Tighten the lower transaxle-to-engine mounting bolts to 38-51 Nm (28-38 ft. lbs.).
40. Install the three rear transaxle support bracket bolts.
41. Tighten the rear transaxle support bracket bolts to 67-93 Nm (50-68 ft. lbs.).
42. Lower the vehicle.
43. Install the fuel filter and the two fuel filter nuts.
44. Tighten the fuel filter nuts to 8-10 Nm (71-88 inch lbs.).
45. Install the seven upper transaxle-to-engine bolts. Tighten the upper transaxle bolts to 68-99 Nm (50-73 ft. lbs.).
46. Install the two upper starter motor bolts. Tighten the upper starter motor bolts to 35-51 Nm (28-38 ft. lbs.).
47. Remove the Rotunda Three-Bar Engine Support 014-00750 or equivalent.
48. Install the clutch slave cylinder and the two attaching bolts. Install the lower clutch slave cylinder tube. Tighten the clutch slave cylinder bolts to 16-22 Nm (12-16 ft. lbs.).
49. Connect the backup lamp switch and the park/neutral position (PNP) switch electrical connectors.
50. Connect the vehicle speed sensor (VSS) electrical connector.
51. Install the transaxle ground straps.
52. Install the battery tray and the battery. Tighten the battery tray mounting bolts to 8-10 Nm (71-88 inch lbs.).
53. Install the engine air cleaner (ACL) and the engine air cleaner intake tube.
54. for proper filling of the transmission fluid.
55. Bleed the clutch hydraulic system.