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Section 1 (Manual Transmission): Installation: Transaxle: Installation

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  1. Position the transaxle to the engine. Install the 10 transaxle-to-engine bolts.
    • Tighten to 47 Nm (35 lb-ft).
    2. Fig 1: Locating Transaxle-To-Engine Bolts
    GF0040111Courtesy of FORD MOTOR CO.
  2. Install the exhaust flexible pipe. For additional information, refer to EXHAUST SYSTEM article.
  3. Connect the clutch hydraulic tube and install the clip.
    4. Fig 2: Locating Clutch Hydraulic Line Clip
    GF0040110Courtesy of FORD MOTOR CO.
  4. Tighten the starter bolts.
    • Tighten to 25 Nm (18 lb-ft).
    5. Fig 3: Locating Starter Bolts
    GF0040109Courtesy of FORD MOTOR CO.
    NOTE: Install a new halfshaft snap ring.
  5. Using a seal protector, install the LH halfshaft into the transaxle.
    6. NOTE: Install a new halfshaft snap ring.
  6. Using a seal protector, install the RH halfshaft into the transaxle.
    7. NOTE: Install a new intermediate shaft center bearing cap and locknuts.
  7. Install the new intermediate shaft center bearing cap and the locknuts.
    • Tighten to 25 Nm (18 lb-ft).
    8. Fig 4: Locating Locknuts And Intermediate Shaft Center Bearing Cap
    GF0040106Courtesy of FORD MOTOR CO.
  8. Connect the vehicle speed sensor (VSS) electrical connector.
    9. Fig 5: Locating Vehicle Speed Sensor (VSS) Electrical Connector
    GF0040105Courtesy of FORD MOTOR CO.
    NOTE: Make sure to align the index marks on the subframe to the chassis.
  9. Position the subframe into the vehicle, install the 6 subframe bolts.
    • Tighten the rear subframe bolts to 200 Nm (148 lb-ft).
    • Tighten the front subframe bolts to 115 Nm (85 lb-ft).
    10. Fig 6: Locating Front And Rear Subframe Bolts
    GF0040103Courtesy of FORD MOTOR CO.
  10. Connect the power steering tubes to the steering gear. Install the power steering tube bolt.
    • Tighten to 23 Nm (17 lb-ft).
    11. Fig 7: Locating Battery Tray Nuts
    GF0040078Courtesy of FORD MOTOR CO.
  11. Install the 2 new stabilizer bar link nuts.
    • Tighten to 50 Nm (37 lb-ft).
    12. Fig 8: Locating Stabilizer Bar Links Strut Nut
    GF0040101Courtesy of FORD MOTOR CO.
  12. Position the lower control arms into the wheel knuckles. Install the 2 new lower control arm bolts and nuts.
    • Tighten to 47 Nm (35 lb-ft).
    13. Fig 9: Locating Lower Control Arms Nuts
    GF0040100Courtesy of FORD MOTOR CO.
  13. Install the 2 new tie-rod end nuts.
    • Tighten to 47 Nm (35 lb-ft).
    14. Fig 10: Locating Tie-Rod End Nuts
    GF0040098Courtesy of FORD MOTOR CO.
  14. Install the engine roll restrictor and the 2 engine roll restrictor bolts.
    • Tighten to 70 Nm (52 lb-ft).
    15. Fig 11: Identifying Engine Roll Restrictor Bolts
    GF0043416Courtesy of FORD MOTOR CO.
  15. Position the bracket to the transaxle. Install the lower heated oxygen sensor (HO2S) sensor bracket nut.
    • Tighten to 25 Nm (18 lb-ft).
  16. Install the wheels and tires. For additional information, refer to WHEELS AND TIRES article.
  17. Install the 3 upper transaxle-to-engine bolts.
    • Tighten to 47 Nm (35 lb-ft).
  18. Install the upper sensor bracket nut. Connect the HO2S and the catalyst monitor sensor electrical connectors.
    • Tighten to 25 Nm (18 lb-ft).
    19. Fig 12: Identifying Upper Sensor Bracket Nut
    GF0043415Courtesy of FORD MOTOR CO.
  19. Connect the clutch hydraulic tube and grommet into the retaining bracket.
  20. Install the power steering tube clamp bolt.
    21. Fig 13: Identifying Power Steering Tube Clamp Bolt
    G04517273Courtesy of FORD MOTOR CO.
    NOTE: An audible click will be heard when the gearshift cables are correctly seated in the retaining bracket.
  21. Install the gearshift levers into the brackets.
    1. Connect the shift cable into the retaining bracket.
    2. Connect the selector cable into the retaining bracket.
    22. Fig 14: Disconnecting Cables
    GF0040091Courtesy of FORD MOTOR CO.
  22. Connect the gearshift cables to the transaxle.
    1. Connect the shift cable to the shift mass.
    2. Connect the selector cable to the selector lever.
    23. Fig 15: Identifying Shift Cable And Selector Cable
    GF0040087Courtesy of FORD MOTOR CO.
  23. Connect the reverse lamp switch electrical connector.
    24. Fig 16: Locating Reverse Lamp Switch Electrical Connector
    GF0040086Courtesy of FORD MOTOR CO.
  24. Install the LH transaxle support insulator bracket and the 3 LH transaxle support insulator bracket bolts.
    • Tighten to 80 Nm (59 lb-ft).
    25. Fig 17: Identifying Transaxle Support Insulator Bracket Bolts
    GF0043414Courtesy of FORD MOTOR CO.
  25. Install the PCM/battery support bracket.
  26. Install the LH transaxle support insulator and the 5 LH transaxle support insulator nuts. Install the 3 PCM/battery support bracket bolts.
    • Tighten the LH transaxle support insulator center nut to 150 Nm (111 lb-ft).
    • Tighten the 4 LH transaxle support insulator outer nuts to 48 Nm (35 lb-ft).
    27. Fig 18: Identifying LH Transaxle Support Insulator Nuts
    GF0040084Courtesy of FORD MOTOR CO.
  27. Install the PCM and the PCM bolt and nut. Connect the PCM electrical connectors.
  28. Install the resonator and the 2 resonator bolts.
    • Tighten to 11 Nm (8 lb-ft).
    29. Fig 19: Locating Resonator Bolts
    GF0040080Courtesy of FORD MOTOR CO.
  29. Install the intake air hose.
    1. Connect the crankcase ventilation hose.
    2. Connect the booster bleed hose.
    3. Tighten the intake air hose clamps.
      • Tighten to 4 Nm (35 lb-in).
    30. Fig 20: Identifying Crankcase Ventilation Hose, Booster Bleed Hose And Clamps
    GF0040079Courtesy of FORD MOTOR CO.
  30. Install the battery tray and the 3 battery tray nuts. Connect the 2 wiring harness pushpins.
    • Tighten to 12 Nm (9 lb-ft).
    31. Fig 21: Locating Battery Tray Nuts
    GF0040078Courtesy of FORD MOTOR CO.
  31. Install the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
  32. Install the steering column shaft bolt.
    • Tighten to 28 Nm (21 lb-ft).
    33. Fig 22: Locating Steering Column Shaft Bolt
    GF0040088Courtesy of FORD MOTOR CO.
  33. Check and, if necessary, fill the transmission with the specified fluid. The total fill capacity is 1.9L (4.0 pt). Apply sealant to the fill plug threads and install the fill plug.
  34. Fill and bleed the power steering system. For additional information, refer to STEERING SYSTEM - GENERAL INFORMATION article.
    35. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury.
    CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled on a painted or plastic surface, wash the affected area immediately with cold water.
  35. Fill the brake fluid reservoir to the specified level. Bleed the clutch hydraulic system. For additional information, refer to MANUAL TRANSAXLE/TRANSMISSION AND CLUTCH - GENERAL INFORMATION article.
  36. Adjust the gearshift cables. For additional information, refer to MANUAL TRANSAXLE/TRANSMISSION AND CLUTCH - GENERAL INFORMATION article.
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