I'm right in the middle of pulling the Zetec out of my daughters '95 Contour (automatic) and I need some advice. My book says to drop the motor and trans out the bottom as a unit and seperate it on the floor but it sure looks to me at this stage (motor pretty much stripped to a bare block and exhaust removed) that I can seperate it in the car and pull the motor out the top by itself. Is this possible or am I opening a can of worms. Really need some input on this from someone thats done this before. Thanks a bunch.
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URGENT: Engine Removal ??
- Thread starter BillC
- Start date
saturnspeed_12
CEG'er
with an auto, its easier. unbolt the torque converter from the flexplate, slide trans over as much as possible, and it should lift out.
i did this with a manual trans in place that i couldnt move because i had a seized axle nut so i couldnt move the halfshaft out of the way. i didnt have much room, and scraped the frame with the crank pulley on the way out. remove crank pulley and get more room to help out.
i did this with a manual trans in place that i couldnt move because i had a seized axle nut so i couldnt move the halfshaft out of the way. i didnt have much room, and scraped the frame with the crank pulley on the way out. remove crank pulley and get more room to help out.
From 1996 Ford CD for 2.0L,
Engine
Removal
1. Disconnect negative battery cable.
2. Recover the A/C system.
3. Remove two nuts and one bolt from engine air cleaner resonator. Remove air cleaner housing rubber O-ring retainer. Disconnect Mass Air Flow (MAF) sensor and Intake Air Temperature (IAT) sensor connectors.
4. Disconnect air cleaner housing inlet vent tube from valve cover. Remove as an assembly air cleaner resonators, inlet duct and tube, air cleaner outlet tube, and air cleaner housing.
5. Disconnect throttle and cruise control cables from throttle cam. Remove retaining clip from the throttle cable and bracket. Disconnect cruise cable from grommet at bracket and retainers near the coolant hose. Position cables aside.
6. Disconnect evaporative emission hose from connector at the rear of engine. Disconnect backpressure transducer-to-EGR tube and EGR valve hoses.
7. Disconnect radio capacitor, coil pack, and fuel injector harness connectors. Remove harness locator from coil pack.
8. Disconnect fuel lines.
9. Remove oil level indicator, three exhaust heat shield bolts, and air conditioning hose bracket nut. Position bracket aside. Remove exhaust heat shield stud and shield.
10. Remove four nuts from Three Way Catalytic (TWC) converter. Disconnect HO2S connector at top of radiator.
11. Disconnect water temperature indicator sensor connector at the bottom of thermostat housing and crankshaft sensor connector at rear of engine block.
12. Disconnect power steering pressure sensor connector. Remove bolt retaining ground wire to front engine insulator bracket. Remove power steering pressure line insulator bracket bolt and nut from engine lifting eye. Remove bolt from power steering pump bracket.
13. Disconnect generator connectors and remove battery wire nut. Position connectors and wire aside.
14. Disconnect vacuum hoses from intake manifold under throttle body. Remove two bolts from EGR pressure transducer and two bolts from EGR vacuum regulator valve solenoid sensor. Position transducer and sensor aside.
15. Remove three screws securing wiring harness to rear of intake manifold. Remove cover and one cable nut at alternator fuse. Position both aside.
16. Note: Record the location of ground cable for installation.
Remove three starter bolts.
17. Raise vehicle.
18. Remove air deflector screws and deflector.
19. Drain cooling system.
20. Remove oil drain plug and drain oil. Using a new drain plug gasket, install plug. Tighten plug to 21-28 N-m (15-21 lb-ft).
21. Disconnect EGR valve tube fitting from TWC converter. Loosen clamp from converter assembly. Remove clamp nuts and lower exhaust from manifold. Remove exhaust bracket nuts and disconnect HO2S connector.
22. Remove lower transaxle-to-engine bolts.
23. Remove two engine-to-transaxle spacer plate bolts and remove plate. Remove coolant tube bolt at oil pan.
24. Remove intermediate shaft bearing bracket nuts and washer. Position coolant tube bracket aside. Remove bracket-to-engine bolts and position brackets aside.
25. Disconnect knock sensor connector, oil sending unit connector, and engine block heater (if equipped). Remove battery cable and solenoid wire nuts from starter. Remove starter and disconnect brake booster hose from intake manifold.
26. Remove two screws from right splash shield and shield. Remove drive belt.
27. Remove A/C compressor.
28. Rotate torque converter to align and remove four torque converter-to-flexplate nuts.
29. Lower vehicle.
30. Compress hose clamps at cooling system reservoir and remove hoses. Remove two screws and reservoir.
31. Compress clamps and remove heater hoses from tube at EGR valve and from coolant tube. Compress clamp and remove upper radiator hose from engine.
32. Remove six front engine support insulator-to-engine bracket nuts and bracket. Remove front engine support insulator bolts and insulator.
33. Position a floor crane and secure it to engine lifting brackets. Slightly raise engine.
34. Remove four power steering pump-to-bracket bolts and position pump aside.
35. Compress and position lower radiator hose clamp and remove hose from engine.
36. Remove two remaining transaxle-to-engine bolts. Separate engine from transaxle and lift engine out of vehicle.
Installation
1. Position torque converter to align it with flexplate.
2. Secure engine to floor crane and raise engine into position. Lower engine to align it with transaxle, noting alignment of torque converter studs to flexplate.
3. Position battery cable brackets and install two top transaxle bolts. Tighten bolts to 34-46 N-m (25-34 lb-ft).
4. Install lower radiator hose to water pump. Compress and position hose clamp.
5. Position power steering pump and install four bolts. Tighten bolts to 25 N-m (18 lb-ft).
6. Position front engine support insulator to fender apron. Position power steering return hose bracket to top insulator and install bolts. Tighten bolts to 70-95 N-m (52-70 lb-ft).
7. Install front insulator bracket and six new insulator nuts. Tighten nuts to 70-95 N-m (52-70 lb-ft).
8. Disconnect floor crane from engine lifting eyes and remove crane.
9. Raise vehicle.
10. Install four new torque converter-to-flexplate nuts. Tighten nuts to 33-44 N-m (24-30 lb-ft).
11. Position spacer plate and install bolts. Tighten bolts to 8-12 N-m (71-106 lb-in). Install lower engine-to-transaxle bolts. Tighten bolts to 34-46 N-m (25-34 lb-ft).
12. Connect brake booster hose to intake manifold. Prior to starter installation, position starter motor wiring harness towards engine. Position starter motor and loosely install lower bolt.
13. Position wiring harness to starter and install two nuts. Tighten S-terminal nut to 5-6 N-m (44-53 lb-in) and B-terminal nut to 11-13 N-m (97-115 lb-in). Connect oil sending unit connector, knock sensor connector, and block heater (if equipped).
14. Position intermediate shaft support bracket to engine and install bolts. Tighten bolts to 21-32 N-m (15-23 lb-ft). Position coolant tube, washer, and bearing shield. Install nuts and tighten to 24-30 N-m (17-22 lb-ft).
15. Install A/C compressor and install four bolts. Tighten bolts to 20-30 N-m (15-22 lb-ft).
16. Install serpentine drive belt. Position right splash shield and securely install two screws.
17. Position coolant tube and install bolt to front of oil pan. Tighten bolt to 8-12 N-m (71-106 lb-in).
18. Using a new exhaust converter inlet gasket, position TWC converter and loosely install two front nuts to exhaust manifold.
19. Install EGR tube fitting to TWC converter. Install exhaust bracket nuts to front of converter. Position rear bracket and install nuts. Tighten nuts to 20-30 N-m (15-22 lb-ft). Securely install converter clamp and connect HO2S connector.
20. Position air deflector. Securely install screws.
21. Lower vehicle.
22. Position ground cable and install two remaining starter bolts. Tighten lower bolt and tighten all bolts to 20-27 N-m (15-20 lb-ft).
23. Install three screws securing wiring harness at the rear of intake manifold. Position battery cable at alternator fuse and securely install nut. Install cover.
24. Position cables, connect generator connectors, and install cable nut.
25. Connect vacuum hoses to intake manifold under throttle body. Securely install two screws to EGR pressure transducer and EGR vacuum regulator valve solenoid sensors.
26. Connect power steering pressure sensor connector. Position ground wire to front engine insulator bracket and securely install bolt.
27. Position power steering pressure line insulator brackets to lifting eye and power steering pump bracket. Securely install bolt and nut at lifting eye. Install bolt to power steering pump bracket and tighten it to 25 N-m (18 lb-ft).
28. Connect water temperature indicator sensor connector at bottom of thermostat housing and crankshaft sensor connector at rear of engine block.
29. Install two remaining nuts and tighten front nuts at TWC converter. Tighten four nuts to 34-46 N-m (26-33 lb-ft). Connect HO2S connector at top of radiator.
30. Install coolant tube to heater hose at thermostat housing and position clamp. Install the upper radiator hose and position the clamp.
31. Position exhaust heat shield, coolant tube, and hose retainers. Install three heat shield bolts and one stud. Tighten retainers to 8-11 N-m (71-97 lb-in). Position A/C hose bracket to stud and securely install nut.
32. Connect fuel pressure and return hoses at right rear corner of engine and install safety clips.
33. Connect radio capacitor, coil pack, fuel injector connectors, and harness locator to coil pack.
34. Install heater hose at EGR valve and position clamp.
35. Connect vacuum hose to EGR valve. Connect evaporative emission hose. Connect hoses from the EGR transducer to EGR tubes.
36. Position cooling system reservoir and install hoses. Position clamps. Securely install two screws.
37. Connect throttle and cruise control cables to bracket. Install retaining clip to throttle cable and connect cables to cam. Connect cruise cable to retainers at coolant hose.
38. Position air cleaner assembly. Install two nuts, one bolt, and one rubber retaining O-ring. Connect MAF and IAT sensors. Install air cleaner housing inlet vent tube to valve cover.
39. Fill engine with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP meeting Ford specification WSS-M2C153-G.
40. Connect negative battery cable.
41. Fill cooling system.
42. Recharge A/C system.
Engine
Removal
1. Disconnect negative battery cable.
2. Recover the A/C system.
3. Remove two nuts and one bolt from engine air cleaner resonator. Remove air cleaner housing rubber O-ring retainer. Disconnect Mass Air Flow (MAF) sensor and Intake Air Temperature (IAT) sensor connectors.
4. Disconnect air cleaner housing inlet vent tube from valve cover. Remove as an assembly air cleaner resonators, inlet duct and tube, air cleaner outlet tube, and air cleaner housing.
5. Disconnect throttle and cruise control cables from throttle cam. Remove retaining clip from the throttle cable and bracket. Disconnect cruise cable from grommet at bracket and retainers near the coolant hose. Position cables aside.
6. Disconnect evaporative emission hose from connector at the rear of engine. Disconnect backpressure transducer-to-EGR tube and EGR valve hoses.
7. Disconnect radio capacitor, coil pack, and fuel injector harness connectors. Remove harness locator from coil pack.
8. Disconnect fuel lines.
9. Remove oil level indicator, three exhaust heat shield bolts, and air conditioning hose bracket nut. Position bracket aside. Remove exhaust heat shield stud and shield.
10. Remove four nuts from Three Way Catalytic (TWC) converter. Disconnect HO2S connector at top of radiator.
11. Disconnect water temperature indicator sensor connector at the bottom of thermostat housing and crankshaft sensor connector at rear of engine block.
12. Disconnect power steering pressure sensor connector. Remove bolt retaining ground wire to front engine insulator bracket. Remove power steering pressure line insulator bracket bolt and nut from engine lifting eye. Remove bolt from power steering pump bracket.
13. Disconnect generator connectors and remove battery wire nut. Position connectors and wire aside.
14. Disconnect vacuum hoses from intake manifold under throttle body. Remove two bolts from EGR pressure transducer and two bolts from EGR vacuum regulator valve solenoid sensor. Position transducer and sensor aside.
15. Remove three screws securing wiring harness to rear of intake manifold. Remove cover and one cable nut at alternator fuse. Position both aside.
16. Note: Record the location of ground cable for installation.
Remove three starter bolts.
17. Raise vehicle.
18. Remove air deflector screws and deflector.
19. Drain cooling system.
20. Remove oil drain plug and drain oil. Using a new drain plug gasket, install plug. Tighten plug to 21-28 N-m (15-21 lb-ft).
21. Disconnect EGR valve tube fitting from TWC converter. Loosen clamp from converter assembly. Remove clamp nuts and lower exhaust from manifold. Remove exhaust bracket nuts and disconnect HO2S connector.
22. Remove lower transaxle-to-engine bolts.
23. Remove two engine-to-transaxle spacer plate bolts and remove plate. Remove coolant tube bolt at oil pan.
24. Remove intermediate shaft bearing bracket nuts and washer. Position coolant tube bracket aside. Remove bracket-to-engine bolts and position brackets aside.
25. Disconnect knock sensor connector, oil sending unit connector, and engine block heater (if equipped). Remove battery cable and solenoid wire nuts from starter. Remove starter and disconnect brake booster hose from intake manifold.
26. Remove two screws from right splash shield and shield. Remove drive belt.
27. Remove A/C compressor.
28. Rotate torque converter to align and remove four torque converter-to-flexplate nuts.
29. Lower vehicle.
30. Compress hose clamps at cooling system reservoir and remove hoses. Remove two screws and reservoir.
31. Compress clamps and remove heater hoses from tube at EGR valve and from coolant tube. Compress clamp and remove upper radiator hose from engine.
32. Remove six front engine support insulator-to-engine bracket nuts and bracket. Remove front engine support insulator bolts and insulator.
33. Position a floor crane and secure it to engine lifting brackets. Slightly raise engine.
34. Remove four power steering pump-to-bracket bolts and position pump aside.
35. Compress and position lower radiator hose clamp and remove hose from engine.
36. Remove two remaining transaxle-to-engine bolts. Separate engine from transaxle and lift engine out of vehicle.
Installation
1. Position torque converter to align it with flexplate.
2. Secure engine to floor crane and raise engine into position. Lower engine to align it with transaxle, noting alignment of torque converter studs to flexplate.
3. Position battery cable brackets and install two top transaxle bolts. Tighten bolts to 34-46 N-m (25-34 lb-ft).
4. Install lower radiator hose to water pump. Compress and position hose clamp.
5. Position power steering pump and install four bolts. Tighten bolts to 25 N-m (18 lb-ft).
6. Position front engine support insulator to fender apron. Position power steering return hose bracket to top insulator and install bolts. Tighten bolts to 70-95 N-m (52-70 lb-ft).
7. Install front insulator bracket and six new insulator nuts. Tighten nuts to 70-95 N-m (52-70 lb-ft).
8. Disconnect floor crane from engine lifting eyes and remove crane.
9. Raise vehicle.
10. Install four new torque converter-to-flexplate nuts. Tighten nuts to 33-44 N-m (24-30 lb-ft).
11. Position spacer plate and install bolts. Tighten bolts to 8-12 N-m (71-106 lb-in). Install lower engine-to-transaxle bolts. Tighten bolts to 34-46 N-m (25-34 lb-ft).
12. Connect brake booster hose to intake manifold. Prior to starter installation, position starter motor wiring harness towards engine. Position starter motor and loosely install lower bolt.
13. Position wiring harness to starter and install two nuts. Tighten S-terminal nut to 5-6 N-m (44-53 lb-in) and B-terminal nut to 11-13 N-m (97-115 lb-in). Connect oil sending unit connector, knock sensor connector, and block heater (if equipped).
14. Position intermediate shaft support bracket to engine and install bolts. Tighten bolts to 21-32 N-m (15-23 lb-ft). Position coolant tube, washer, and bearing shield. Install nuts and tighten to 24-30 N-m (17-22 lb-ft).
15. Install A/C compressor and install four bolts. Tighten bolts to 20-30 N-m (15-22 lb-ft).
16. Install serpentine drive belt. Position right splash shield and securely install two screws.
17. Position coolant tube and install bolt to front of oil pan. Tighten bolt to 8-12 N-m (71-106 lb-in).
18. Using a new exhaust converter inlet gasket, position TWC converter and loosely install two front nuts to exhaust manifold.
19. Install EGR tube fitting to TWC converter. Install exhaust bracket nuts to front of converter. Position rear bracket and install nuts. Tighten nuts to 20-30 N-m (15-22 lb-ft). Securely install converter clamp and connect HO2S connector.
20. Position air deflector. Securely install screws.
21. Lower vehicle.
22. Position ground cable and install two remaining starter bolts. Tighten lower bolt and tighten all bolts to 20-27 N-m (15-20 lb-ft).
23. Install three screws securing wiring harness at the rear of intake manifold. Position battery cable at alternator fuse and securely install nut. Install cover.
24. Position cables, connect generator connectors, and install cable nut.
25. Connect vacuum hoses to intake manifold under throttle body. Securely install two screws to EGR pressure transducer and EGR vacuum regulator valve solenoid sensors.
26. Connect power steering pressure sensor connector. Position ground wire to front engine insulator bracket and securely install bolt.
27. Position power steering pressure line insulator brackets to lifting eye and power steering pump bracket. Securely install bolt and nut at lifting eye. Install bolt to power steering pump bracket and tighten it to 25 N-m (18 lb-ft).
28. Connect water temperature indicator sensor connector at bottom of thermostat housing and crankshaft sensor connector at rear of engine block.
29. Install two remaining nuts and tighten front nuts at TWC converter. Tighten four nuts to 34-46 N-m (26-33 lb-ft). Connect HO2S connector at top of radiator.
30. Install coolant tube to heater hose at thermostat housing and position clamp. Install the upper radiator hose and position the clamp.
31. Position exhaust heat shield, coolant tube, and hose retainers. Install three heat shield bolts and one stud. Tighten retainers to 8-11 N-m (71-97 lb-in). Position A/C hose bracket to stud and securely install nut.
32. Connect fuel pressure and return hoses at right rear corner of engine and install safety clips.
33. Connect radio capacitor, coil pack, fuel injector connectors, and harness locator to coil pack.
34. Install heater hose at EGR valve and position clamp.
35. Connect vacuum hose to EGR valve. Connect evaporative emission hose. Connect hoses from the EGR transducer to EGR tubes.
36. Position cooling system reservoir and install hoses. Position clamps. Securely install two screws.
37. Connect throttle and cruise control cables to bracket. Install retaining clip to throttle cable and connect cables to cam. Connect cruise cable to retainers at coolant hose.
38. Position air cleaner assembly. Install two nuts, one bolt, and one rubber retaining O-ring. Connect MAF and IAT sensors. Install air cleaner housing inlet vent tube to valve cover.
39. Fill engine with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP meeting Ford specification WSS-M2C153-G.
40. Connect negative battery cable.
41. Fill cooling system.
42. Recharge A/C system.
Last edited:
And for the transaxle,
From 1996 Ford CD
2.0 L. Automatic Transaxle Removal.
1. Disconnect the negative and positive battery cables. Remove battery hold-down nuts, hold-down, and battery.
2. Secure the radiator and fan shroud assembly to the radiator support using mechanic's wire.
3. Remove the air cleaner O-ring resonator from the throttle body. Remove the air cleaner housing rubber O-ring retainer. Disconnect the mass air flow (MAF) and intake air temperature (IAT) sensor connectors. Disconnect the air cleaner breather inlet tube from the valve cover. Remove the air cleaner box.
4. CAUTION: Since the struts must be moved to remove the halfshafts, the struts must be loosened to prevent damage to the strut piston rod.
Loosen the left and right front shock absorber upper mounting nuts five turns, counterclockwise.
5. Disconnect the shift cable from the manual shift lever. Remove two bolts retaining the shift cable bracket to the transaxle case and position the cable out of the way.
6. Remove the bolt retaining the ground wire at the top of the transmission. Remove the wire harness from the retaining clip at the top of the transmission.
7. Remove the oil level indicator, three exhaust heat shield bolts, and A/C line nut. Position the A/C line bracket aside. Remove the exhaust heat stud and heat shield.
8. Remove the four nuts from the top of the three way catalytic (TWC) converter.
9. Disconnect the transmission range (TR) sensor connector. Remove two bolts and the TR sensor. Disconnect the transaxle harness 10-pin connector from the transaxle.
10. Remove the two upper bell housing bolts and two upper starter bolts.
11. Remove the transmission fluid level indicator and disconnect the vacuum tube from the brake booster.
12. Support the engine with Three-Bar Engine Support 014-00750 or equivalent following manufacturer's instructions.
13. Remove the four upper transaxle support insulator bracket nuts.
14. Remove the three bolts retaining the upper transaxle support to the inner fenderwell and remove the upper transaxle support insulator.
15. Lock the steering wheel to the right, approximately one quarter of a turn.
16. Raise the vehicle.
17. Remove the front wheel assemblies.
18. Position a drain pan and drain the transaxle.
19. Remove the lower air deflector retainers and the deflector.
20. Remove the four bolts that retain the left and right lower radiator support brackets to the front of the subframe. Turn the brackets forward.
21. Install Exhaust Holder Tool T94T-6000-AH to the flex tube.
22. WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT HAS COOLED. USE SPECIAL CARE WHEN WORKING AROUND THE TWC CONVERTER. THE CONVERTER HEATS TO A HIGH TEMPERATURE AFTER ONLY A SHORT PERIOD OF ENGINE OPERATION. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
Remove the nuts from the outlet flange of the TWC converter. Remove the muffler-to-converter outlet gasket from the TWC converter.
23. Disconnect the EGR valve tube fitting from the TWC converter. Disconnect the HO2S connector pushpin from the right subframe and disconnect the HO2S connector.
24. Loosen the clamp from the TWC converter assembly. Remove the bracket nuts and brackets. Disconnect the TWC converter assembly from the rubber exhaust hanger and remove it from the vehicle.
25. At the driver side front corner of the vehicle, remove the two bolts that retain the A/C suction accumulator/drier to the subframe.
26. Remove the nut that retains the power steering cooler lines to the right front of the subframe. Remove the two bolts that retain the cooler lines to the rear of the subframe.
27. Remove the steering gear pinch bolt.
28. Remove and discard the right and left pinch bolts and nuts from the steering knuckles at the lower arms.
29. Using Rotunda Tie Rod End Remover TOOL-3290-D, disconnect the left and right tie rod ends from the front wheel knuckles.
30. Remove the left and right front stabilizer bar link nuts from the front strut assemblies. Disconnect both front stabilizer bar links from the front strut assemblies.
31. Support the lower half of the engine with a ratchet strap to keep the engine from rolling forward.
32. Remove the through bolts that retain the left and right front engine support insulators to the subframe.
33. Position a drain pan under the oil cooler. Disconnect the power steering hoses from the oil cooler. Drain the power steering fluid. Install line caps.
34. Remove the two screws that retain the bumper cover braces to the right and left sides of the subframe. Rotate the bumper cover braces forward.
35. Remove the ratchet strap from the vehicle and position Rotunda Powertrain Lift 014-00765 or equivalent with wood blocks (approximately 1016 mm [ 40 inches] in length) secured to the lift under the subframe.
36. Remove the four subframe-to-body bolts.
37. Allow the subframe to lower slightly. Disconnect the power steering pressure and return hoses from the steering gear. Install line caps. Gently pry the lower control arms from the steering knuckles and the steering gear coupler from the steering gear. Lower and remove the subframe.
38. Disconnect the transaxle cooler inlet line from the transaxle case as shown. Remove the transaxle cooler inlet line bracket bolt from the transaxle pump face.
39. Disconnect the transaxle cooler outlet line from the transaxle case as shown.
40. Using Impact Slide Hammer T50T-100-A, CV Joint Puller Extension T86P-3514-A2, and CV Joint Puller T86P-3514-A1, disconnect the left halfshaft from the transaxle and position it aside, using mechanic's wire or equivalent. Remove the intermediate shaft bearing bracket nuts and washers. Position the coolant tube bracket aside amd remove the intermediate shaft bearing bracket. Disconnect the intermediate shaft and halfshaft as an assembly from the transaxle. Using mechanic's wire, position the right halfshaft aside.
41. Disconnect the vehicle speed sensor (VSS) and turbine shaft speed (TSS) sensor connectors at the transaxle pump face. Remove the TSS harness from the retaining clips.
42. Remove the right front splash to access the crankshaft pulley.
43. At the right rear corner of the engine, remove the rubber inspection cover from the transaxle-to-engine spacer plate. Rotate the torque converter and remove four torque converter-to-flexplate nuts.
44. Lower the vehicle.
45. Remove the four front engine support insulator-to-engine bracket nuts.
46. Remove the necessary wire harness retaining clips at the bulkhead to prevent damage to the wiring harness, as shown.
47. Note: Mark the transaxle pump face-to-frame member for installation reference.
Slightly lower the front of the engine, using the Three-Bar Engine Support. Lower the transaxle until the pump face is level with the left frame member, as shown.
48. Raise the vehicle.
49. Position a transmission jack under the vehicle. Raise the jack and position an adapter. Secure the adapter to the transaxle.
50. Remove the lower starter motor bolt. Remove the five remaining lower bolts that retain the transaxle to the engine.
51. CAUTION: The torque converter can fall out of the transaxle if the assembly is tilted.
Separate the transaxle from the engine and carefully lower the transaxle from the vehicle.
Automatic Tranaxle Reinstallation for 2.0 L
1. CAUTION: To avoid damage, do not allow the transaxle to get into a nose-down position, as this will cause the torque converter to move forward and disengage from the transaxle.
Position the jack and transaxle under the vehicle.
2. Place a straightedge on the transaxle flange as shown. With the torque converter properly installed, there will be at least a 10 mm (0.4 inch) air gap between the straightedge and converter.
3. Raise the transaxle into place.
4. Looking through the inspection hole in the transaxle-to-engine separator plate, align the torque converter studs with the mating holes of the flexplate and the transaxle with the engine.
5. Install five lower transaxle-to-engine bolts. Tighten the bolts to 55-68 N-m (41-50 lb-ft). Position the starter motor. Install the lower starter bolt. Tighten the bolt to 20-27 N-m (15-20 lb-ft).
6. Rotate the torque converter and install four new torque converter-to-flexplate nuts. Tighten the nuts to 33-40 N-m (24-30 lb-ft). Install the access plug. Position the right front splash shield and install the retainers.
7. Remove the adapter bolt from the transaxle. Lower and remove the transmission jack.
8. Install a new circlip on left halfshaft. Install the left halfshaft. Install the right halfshaft. Position the intermediate shaft bearing retainer, cooling tube bracket, and copper washer on the mounting stud. Install the heat shield and nuts. Tighten the nuts to 24-30 N-m (18-22 lb-ft).
9. Partially lower the vehicle.
10. Use Rotunda Three-Bar Engine Support 014-00750 or equivalent to raise the engine. Position the alignment studs through the front engine insulator while raising the engine and align the transaxle reference marks with the frame member.
11. Raise the vehicle.
12. Remove the old Teflon® seals from both power steering pressure and return hose unions and install new seals.
13. Install the transaxle inlet and outlet cooler lines. Tighten the fittings to 23 N-m (17 lb-ft). Install the transaxle cooler inlet line bracket at the transaxle pump face. Tighten the bolt to 20-30 N-m (15-22 lb-ft).
14. Remove the left engine support insulator from the subframe and loosely install Powertrain Alignment Gauge T94P-6000-AH to the subframe. Install Subframe Alignment Pin Set T94P-2100-AH into the subframe and body alignment holes.
15. Position the subframe and Rotunda Powertrain Lift 014-00765 or equivalent under the vehicle.
16. Lift and align the subframe to the body. Install the left and right ball joints into the steering knuckles and position the steering gear to the steering column. Route the power steering pressure and return hoses into position at the rear of the subframe. Install four subframe-to-body bolts. Tighten the bolts to 110-150 N-m (81-111 lb-ft).
17. Remove the alignment tools from the subframe. Lower and remove the powertrain lift.
18. Lower the vehicle.
19. Using the three-bar engine support, raise the engine and transaxle into position.
20. Raise the vehicle.
21. Position the transmission jack under the vehicle and raise it to assist in the through bolt installation.
22. Loosen the right engine support insulator from the subframe and loosely install the right through bolt. Loosely install the left through bolt through the powertrain alignment gauge. Tighten the powertrain alignment gauge. Remove the transmission jack. Tighten the right engine support insulator bolts to 41-55 N-m (30-41 lb-ft). Tighten the left through bolt.
23. Partially lower the vehicle.
24. Install new lock nuts to the front engine support insulator. Tighten the nuts to 77-103 N-m (56-76 lb-ft).
25. Position the engine and transmission support insulator and install three bolts to the front fender apron. Tighten the bolts to 70-95 N-m (52-71 lb-ft).
26. Install new engine and transmission support insulator lock nuts to the transaxle. Tighten the nuts to 41-55 N-m (30-41 lb-ft).
27. Remove the Three-Bar Engine Support.
28. Partially raise the vehicle.
29. CAUTION: The right front engine support insulator must be centered in the transaxle bracket and must be in proper front-to-rear alignment.
Observe the position of the right front engine support insulator. Install the right insulator through bolt and tighten it to 103-137 N-m (76-101 lb-ft).
30. Remove the left insulator through bolt. Remove the powertrain alignment gauge bolts and gauge.
31. Position the left engine support insulator to the subframe and install the bolts.
32. CAUTION: The left engine support insulator must be centered in the transaxle bracket and must be in proper front-to-rear alignment.
Observe the position of the left engine support insulator. Install the left insulator through bolt and tighten it to 103-137 N-m (76-101 lb-ft).
33. Install the steering column pinch bolt. Tighten the bolt to 20-27 N-m (15-20 lb-ft).
34. Partially lower the vehicle.
35. Torque the power steering pressure and return lines to the steering gear.
36. Partially raise the vehicle.
37. Install the power steering cooler line nut to the right front of the subframe. Install the two bolts retaining the cooler lines to the rear of the subframe. Remove the oil caps. Install the cooler lines to the oil cooler at the right front of the vehicle and position the clamps.
38. Position the left and right front bumper cover braces to the side of the subframe. Securely install the bolts.
39. Position the lower left and right radiator support brackets to the subframe. Install four bolts and tighten them to 8-11 N-m (71-97 lb-in).
40. Connect the VSS and TSS sensor connectors.
41. Install a new exhaust converter inlet gasket and the TWC converter. Loosely install the two front converter nuts to the exhaust manifold.
42. Install a new muffler-to-converter gasket on the TWC converter. Position the muffler inlet to the TWC converter outlet and loosely install the nuts on the outlet flange studs of the TWC converter. Securely install the EGR tube fitting.
43. Position the exhaust system on the rubber exhaust hanger. Tighten the muffler inlet flange nuts to 34-46 N-m (25-34 lb-ft). Install the converter bracket and nuts. Tighten the bolts to 8-12 N-m (71-106 lb-in).
44. Press the TWC converter against the exhaust manifold and tighten the converter clamp. Tighten the clamp to 20-30 N-m (15-22 lb-ft). Connect the HO2S connector and install the connector pushpin to the subframe.
45. Remove the flex tube tool from the converter.
46. Position the A/C suction accumulator/drier bracket to the subframe and securely install the bolts.
47. Install new left and right ball joint pinch bolts and nuts. Tighten the retainers to 83 N-m (61 lb-ft).
48. Connect the left and right stabilizer bar links to the front struts. Install the nuts and tighten them to 47 N-m (35 lb-ft).
49. Install the left and right tie rod ends to the steering knuckles. Install the tie rod end nuts and tighten them to 31 N-m (23 lb-ft), then continue to the nearest cotter pin slot. Insert new cotter pins.
50. Position the front air deflector and install the screws.
51. Install the front wheel assemblies.
52. Lower the vehicle.
53. Tighten the left engine support insulator-to-subframe bolts to 41-55 N-m (30-41 lb-ft).
54. Position the wiring harness locating bracket and install the upper transaxle-to-engine bolts. Tighten the bolts to 55-68 N-m (41-50 lb-ft). Position the harness ground eyelet and install two upper starter bolts. Tighten the bolts to 20-25 N-m (15-18 lb-ft). Install the harness in the hold-down at the top of the transaxle.
55. Remove the mechanic's wire retaining the radiator to the upper support.
56. Install all wiring harnesses into the retaining clips that were disconnected during transaxle removal. Install the ground cable and retainer at the top of the transaxle and tighten the retainer to 34-46 N-m (25-34 lb-ft).
57. Install the transaxle fluid level indicator and brake booster vacuum tube to the booster.
58. Place the manual lever in the NEUTRAL position. Position the TR sensor and loosely install the bolts. Using TRS Alignment Tool T97L-70010-A, align the TR sensor. Tighten the bolts to 9-12 N-m (80-106 lb-in).
59. Install two remaining TWC converter nuts to the exhaust manifold. Tighten the four nuts to 34-46 N-m (25-34 lb-ft).
60. Connect the transaxle 10-pin harness connector and TR sensor connectors. Connect the wire harness clips as necessary.
61. Position the exhaust heat shield and A/C line. Install three heat shield bolts and one stud. Tighten the retainers to 8-11 N-m (71-97 lb-in). Position the A/C bracket to the stud, tighten the nut to 8-11 N-m and insert the oil level indicator.
62. Install the shift cable mounting bracket and bolts. Tighten the bolts to 20-25 N-m (15-18 lb-ft). Install the shift cable to the manual lever by pressing the cable end on the stud until a click is heard.
63. Position and secure the gearshift lever in DRIVE. Verify that the transaxle is in the DRIVE position by viewing the TR sensor. The alignment marks will be aligned with the D arrow on the TR sensor body when the transaxle is in the DRIVE position.
64. Raise the vehicle.
65. Remove the four retainers holding the heat shield and remove the shield.
66. Remove the transaxle shift cable from the arm. Depress the two locking tabs on the adjustment lock cylinder and rotate the cylinder. The shift cable is now unlocked and free to slide in the retainer. Make sure an assistant is holding the gearshift lever in the DRIVE position. Grasp the cable forward of the adjustment lock cylinder and move it as necessary to align the cable eye with the pin on the shift arm. Install the shift cable end to the shift arm by pressing on it. Rotate the adjustment lock cylinder clockwise until it snaps into place.
67. Install the heat shield and retainers. Securely tighten the retainers.
68. Lower the vehicle.
69. Release the gearshift. Shift the transaxle through all transmission ranges to make sure the shift control linkage operation is correct and the indicator is properly aligned.
70. Position the air cleaner hold-down bracket and install two bolts. Tighten the bolts to 20-30 N-m (15-22 lb-ft).
71. Position the air cleaner assembly and connect the breather inlet tube to the valve cover. Connect the IAT and MAF sensor connectors. Install the air cleaner bolt, nuts, and rubber O-ring.
72. Install the battery, battery hold-down and nuts. Tighten the nuts to 8-10 N-m (71-89 lb-in).
73. Tighten the left and right front strut upper mount nuts and tighten them to 46 N-m (34 lb-ft).
74. Fill the power steering pump remote fluid reservoir.
75. Connect the battery positive and negative cables.
76. Fill the transaxle to the proper level with Motorcraft MERCON® Multi-Purpose Automatic Transmission Fluid XT-2-QDX or MERCON® equivalent.
77. Check the operation of the transaxle.
78. Check the toe setting and adjust it if necessary.
From 1996 Ford CD
2.0 L. Automatic Transaxle Removal.
1. Disconnect the negative and positive battery cables. Remove battery hold-down nuts, hold-down, and battery.
2. Secure the radiator and fan shroud assembly to the radiator support using mechanic's wire.
3. Remove the air cleaner O-ring resonator from the throttle body. Remove the air cleaner housing rubber O-ring retainer. Disconnect the mass air flow (MAF) and intake air temperature (IAT) sensor connectors. Disconnect the air cleaner breather inlet tube from the valve cover. Remove the air cleaner box.
4. CAUTION: Since the struts must be moved to remove the halfshafts, the struts must be loosened to prevent damage to the strut piston rod.
Loosen the left and right front shock absorber upper mounting nuts five turns, counterclockwise.
5. Disconnect the shift cable from the manual shift lever. Remove two bolts retaining the shift cable bracket to the transaxle case and position the cable out of the way.
6. Remove the bolt retaining the ground wire at the top of the transmission. Remove the wire harness from the retaining clip at the top of the transmission.
7. Remove the oil level indicator, three exhaust heat shield bolts, and A/C line nut. Position the A/C line bracket aside. Remove the exhaust heat stud and heat shield.
8. Remove the four nuts from the top of the three way catalytic (TWC) converter.
9. Disconnect the transmission range (TR) sensor connector. Remove two bolts and the TR sensor. Disconnect the transaxle harness 10-pin connector from the transaxle.
10. Remove the two upper bell housing bolts and two upper starter bolts.
11. Remove the transmission fluid level indicator and disconnect the vacuum tube from the brake booster.
12. Support the engine with Three-Bar Engine Support 014-00750 or equivalent following manufacturer's instructions.
13. Remove the four upper transaxle support insulator bracket nuts.
14. Remove the three bolts retaining the upper transaxle support to the inner fenderwell and remove the upper transaxle support insulator.
15. Lock the steering wheel to the right, approximately one quarter of a turn.
16. Raise the vehicle.
17. Remove the front wheel assemblies.
18. Position a drain pan and drain the transaxle.
19. Remove the lower air deflector retainers and the deflector.
20. Remove the four bolts that retain the left and right lower radiator support brackets to the front of the subframe. Turn the brackets forward.
21. Install Exhaust Holder Tool T94T-6000-AH to the flex tube.
22. WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT HAS COOLED. USE SPECIAL CARE WHEN WORKING AROUND THE TWC CONVERTER. THE CONVERTER HEATS TO A HIGH TEMPERATURE AFTER ONLY A SHORT PERIOD OF ENGINE OPERATION. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
Remove the nuts from the outlet flange of the TWC converter. Remove the muffler-to-converter outlet gasket from the TWC converter.
23. Disconnect the EGR valve tube fitting from the TWC converter. Disconnect the HO2S connector pushpin from the right subframe and disconnect the HO2S connector.
24. Loosen the clamp from the TWC converter assembly. Remove the bracket nuts and brackets. Disconnect the TWC converter assembly from the rubber exhaust hanger and remove it from the vehicle.
25. At the driver side front corner of the vehicle, remove the two bolts that retain the A/C suction accumulator/drier to the subframe.
26. Remove the nut that retains the power steering cooler lines to the right front of the subframe. Remove the two bolts that retain the cooler lines to the rear of the subframe.
27. Remove the steering gear pinch bolt.
28. Remove and discard the right and left pinch bolts and nuts from the steering knuckles at the lower arms.
29. Using Rotunda Tie Rod End Remover TOOL-3290-D, disconnect the left and right tie rod ends from the front wheel knuckles.
30. Remove the left and right front stabilizer bar link nuts from the front strut assemblies. Disconnect both front stabilizer bar links from the front strut assemblies.
31. Support the lower half of the engine with a ratchet strap to keep the engine from rolling forward.
32. Remove the through bolts that retain the left and right front engine support insulators to the subframe.
33. Position a drain pan under the oil cooler. Disconnect the power steering hoses from the oil cooler. Drain the power steering fluid. Install line caps.
34. Remove the two screws that retain the bumper cover braces to the right and left sides of the subframe. Rotate the bumper cover braces forward.
35. Remove the ratchet strap from the vehicle and position Rotunda Powertrain Lift 014-00765 or equivalent with wood blocks (approximately 1016 mm [ 40 inches] in length) secured to the lift under the subframe.
36. Remove the four subframe-to-body bolts.
37. Allow the subframe to lower slightly. Disconnect the power steering pressure and return hoses from the steering gear. Install line caps. Gently pry the lower control arms from the steering knuckles and the steering gear coupler from the steering gear. Lower and remove the subframe.
38. Disconnect the transaxle cooler inlet line from the transaxle case as shown. Remove the transaxle cooler inlet line bracket bolt from the transaxle pump face.
39. Disconnect the transaxle cooler outlet line from the transaxle case as shown.
40. Using Impact Slide Hammer T50T-100-A, CV Joint Puller Extension T86P-3514-A2, and CV Joint Puller T86P-3514-A1, disconnect the left halfshaft from the transaxle and position it aside, using mechanic's wire or equivalent. Remove the intermediate shaft bearing bracket nuts and washers. Position the coolant tube bracket aside amd remove the intermediate shaft bearing bracket. Disconnect the intermediate shaft and halfshaft as an assembly from the transaxle. Using mechanic's wire, position the right halfshaft aside.
41. Disconnect the vehicle speed sensor (VSS) and turbine shaft speed (TSS) sensor connectors at the transaxle pump face. Remove the TSS harness from the retaining clips.
42. Remove the right front splash to access the crankshaft pulley.
43. At the right rear corner of the engine, remove the rubber inspection cover from the transaxle-to-engine spacer plate. Rotate the torque converter and remove four torque converter-to-flexplate nuts.
44. Lower the vehicle.
45. Remove the four front engine support insulator-to-engine bracket nuts.
46. Remove the necessary wire harness retaining clips at the bulkhead to prevent damage to the wiring harness, as shown.
47. Note: Mark the transaxle pump face-to-frame member for installation reference.
Slightly lower the front of the engine, using the Three-Bar Engine Support. Lower the transaxle until the pump face is level with the left frame member, as shown.
48. Raise the vehicle.
49. Position a transmission jack under the vehicle. Raise the jack and position an adapter. Secure the adapter to the transaxle.
50. Remove the lower starter motor bolt. Remove the five remaining lower bolts that retain the transaxle to the engine.
51. CAUTION: The torque converter can fall out of the transaxle if the assembly is tilted.
Separate the transaxle from the engine and carefully lower the transaxle from the vehicle.
Automatic Tranaxle Reinstallation for 2.0 L
1. CAUTION: To avoid damage, do not allow the transaxle to get into a nose-down position, as this will cause the torque converter to move forward and disengage from the transaxle.
Position the jack and transaxle under the vehicle.
2. Place a straightedge on the transaxle flange as shown. With the torque converter properly installed, there will be at least a 10 mm (0.4 inch) air gap between the straightedge and converter.
3. Raise the transaxle into place.
4. Looking through the inspection hole in the transaxle-to-engine separator plate, align the torque converter studs with the mating holes of the flexplate and the transaxle with the engine.
5. Install five lower transaxle-to-engine bolts. Tighten the bolts to 55-68 N-m (41-50 lb-ft). Position the starter motor. Install the lower starter bolt. Tighten the bolt to 20-27 N-m (15-20 lb-ft).
6. Rotate the torque converter and install four new torque converter-to-flexplate nuts. Tighten the nuts to 33-40 N-m (24-30 lb-ft). Install the access plug. Position the right front splash shield and install the retainers.
7. Remove the adapter bolt from the transaxle. Lower and remove the transmission jack.
8. Install a new circlip on left halfshaft. Install the left halfshaft. Install the right halfshaft. Position the intermediate shaft bearing retainer, cooling tube bracket, and copper washer on the mounting stud. Install the heat shield and nuts. Tighten the nuts to 24-30 N-m (18-22 lb-ft).
9. Partially lower the vehicle.
10. Use Rotunda Three-Bar Engine Support 014-00750 or equivalent to raise the engine. Position the alignment studs through the front engine insulator while raising the engine and align the transaxle reference marks with the frame member.
11. Raise the vehicle.
12. Remove the old Teflon® seals from both power steering pressure and return hose unions and install new seals.
13. Install the transaxle inlet and outlet cooler lines. Tighten the fittings to 23 N-m (17 lb-ft). Install the transaxle cooler inlet line bracket at the transaxle pump face. Tighten the bolt to 20-30 N-m (15-22 lb-ft).
14. Remove the left engine support insulator from the subframe and loosely install Powertrain Alignment Gauge T94P-6000-AH to the subframe. Install Subframe Alignment Pin Set T94P-2100-AH into the subframe and body alignment holes.
15. Position the subframe and Rotunda Powertrain Lift 014-00765 or equivalent under the vehicle.
16. Lift and align the subframe to the body. Install the left and right ball joints into the steering knuckles and position the steering gear to the steering column. Route the power steering pressure and return hoses into position at the rear of the subframe. Install four subframe-to-body bolts. Tighten the bolts to 110-150 N-m (81-111 lb-ft).
17. Remove the alignment tools from the subframe. Lower and remove the powertrain lift.
18. Lower the vehicle.
19. Using the three-bar engine support, raise the engine and transaxle into position.
20. Raise the vehicle.
21. Position the transmission jack under the vehicle and raise it to assist in the through bolt installation.
22. Loosen the right engine support insulator from the subframe and loosely install the right through bolt. Loosely install the left through bolt through the powertrain alignment gauge. Tighten the powertrain alignment gauge. Remove the transmission jack. Tighten the right engine support insulator bolts to 41-55 N-m (30-41 lb-ft). Tighten the left through bolt.
23. Partially lower the vehicle.
24. Install new lock nuts to the front engine support insulator. Tighten the nuts to 77-103 N-m (56-76 lb-ft).
25. Position the engine and transmission support insulator and install three bolts to the front fender apron. Tighten the bolts to 70-95 N-m (52-71 lb-ft).
26. Install new engine and transmission support insulator lock nuts to the transaxle. Tighten the nuts to 41-55 N-m (30-41 lb-ft).
27. Remove the Three-Bar Engine Support.
28. Partially raise the vehicle.
29. CAUTION: The right front engine support insulator must be centered in the transaxle bracket and must be in proper front-to-rear alignment.
Observe the position of the right front engine support insulator. Install the right insulator through bolt and tighten it to 103-137 N-m (76-101 lb-ft).
30. Remove the left insulator through bolt. Remove the powertrain alignment gauge bolts and gauge.
31. Position the left engine support insulator to the subframe and install the bolts.
32. CAUTION: The left engine support insulator must be centered in the transaxle bracket and must be in proper front-to-rear alignment.
Observe the position of the left engine support insulator. Install the left insulator through bolt and tighten it to 103-137 N-m (76-101 lb-ft).
33. Install the steering column pinch bolt. Tighten the bolt to 20-27 N-m (15-20 lb-ft).
34. Partially lower the vehicle.
35. Torque the power steering pressure and return lines to the steering gear.
36. Partially raise the vehicle.
37. Install the power steering cooler line nut to the right front of the subframe. Install the two bolts retaining the cooler lines to the rear of the subframe. Remove the oil caps. Install the cooler lines to the oil cooler at the right front of the vehicle and position the clamps.
38. Position the left and right front bumper cover braces to the side of the subframe. Securely install the bolts.
39. Position the lower left and right radiator support brackets to the subframe. Install four bolts and tighten them to 8-11 N-m (71-97 lb-in).
40. Connect the VSS and TSS sensor connectors.
41. Install a new exhaust converter inlet gasket and the TWC converter. Loosely install the two front converter nuts to the exhaust manifold.
42. Install a new muffler-to-converter gasket on the TWC converter. Position the muffler inlet to the TWC converter outlet and loosely install the nuts on the outlet flange studs of the TWC converter. Securely install the EGR tube fitting.
43. Position the exhaust system on the rubber exhaust hanger. Tighten the muffler inlet flange nuts to 34-46 N-m (25-34 lb-ft). Install the converter bracket and nuts. Tighten the bolts to 8-12 N-m (71-106 lb-in).
44. Press the TWC converter against the exhaust manifold and tighten the converter clamp. Tighten the clamp to 20-30 N-m (15-22 lb-ft). Connect the HO2S connector and install the connector pushpin to the subframe.
45. Remove the flex tube tool from the converter.
46. Position the A/C suction accumulator/drier bracket to the subframe and securely install the bolts.
47. Install new left and right ball joint pinch bolts and nuts. Tighten the retainers to 83 N-m (61 lb-ft).
48. Connect the left and right stabilizer bar links to the front struts. Install the nuts and tighten them to 47 N-m (35 lb-ft).
49. Install the left and right tie rod ends to the steering knuckles. Install the tie rod end nuts and tighten them to 31 N-m (23 lb-ft), then continue to the nearest cotter pin slot. Insert new cotter pins.
50. Position the front air deflector and install the screws.
51. Install the front wheel assemblies.
52. Lower the vehicle.
53. Tighten the left engine support insulator-to-subframe bolts to 41-55 N-m (30-41 lb-ft).
54. Position the wiring harness locating bracket and install the upper transaxle-to-engine bolts. Tighten the bolts to 55-68 N-m (41-50 lb-ft). Position the harness ground eyelet and install two upper starter bolts. Tighten the bolts to 20-25 N-m (15-18 lb-ft). Install the harness in the hold-down at the top of the transaxle.
55. Remove the mechanic's wire retaining the radiator to the upper support.
56. Install all wiring harnesses into the retaining clips that were disconnected during transaxle removal. Install the ground cable and retainer at the top of the transaxle and tighten the retainer to 34-46 N-m (25-34 lb-ft).
57. Install the transaxle fluid level indicator and brake booster vacuum tube to the booster.
58. Place the manual lever in the NEUTRAL position. Position the TR sensor and loosely install the bolts. Using TRS Alignment Tool T97L-70010-A, align the TR sensor. Tighten the bolts to 9-12 N-m (80-106 lb-in).
59. Install two remaining TWC converter nuts to the exhaust manifold. Tighten the four nuts to 34-46 N-m (25-34 lb-ft).
60. Connect the transaxle 10-pin harness connector and TR sensor connectors. Connect the wire harness clips as necessary.
61. Position the exhaust heat shield and A/C line. Install three heat shield bolts and one stud. Tighten the retainers to 8-11 N-m (71-97 lb-in). Position the A/C bracket to the stud, tighten the nut to 8-11 N-m and insert the oil level indicator.
62. Install the shift cable mounting bracket and bolts. Tighten the bolts to 20-25 N-m (15-18 lb-ft). Install the shift cable to the manual lever by pressing the cable end on the stud until a click is heard.
63. Position and secure the gearshift lever in DRIVE. Verify that the transaxle is in the DRIVE position by viewing the TR sensor. The alignment marks will be aligned with the D arrow on the TR sensor body when the transaxle is in the DRIVE position.
64. Raise the vehicle.
65. Remove the four retainers holding the heat shield and remove the shield.
66. Remove the transaxle shift cable from the arm. Depress the two locking tabs on the adjustment lock cylinder and rotate the cylinder. The shift cable is now unlocked and free to slide in the retainer. Make sure an assistant is holding the gearshift lever in the DRIVE position. Grasp the cable forward of the adjustment lock cylinder and move it as necessary to align the cable eye with the pin on the shift arm. Install the shift cable end to the shift arm by pressing on it. Rotate the adjustment lock cylinder clockwise until it snaps into place.
67. Install the heat shield and retainers. Securely tighten the retainers.
68. Lower the vehicle.
69. Release the gearshift. Shift the transaxle through all transmission ranges to make sure the shift control linkage operation is correct and the indicator is properly aligned.
70. Position the air cleaner hold-down bracket and install two bolts. Tighten the bolts to 20-30 N-m (15-22 lb-ft).
71. Position the air cleaner assembly and connect the breather inlet tube to the valve cover. Connect the IAT and MAF sensor connectors. Install the air cleaner bolt, nuts, and rubber O-ring.
72. Install the battery, battery hold-down and nuts. Tighten the nuts to 8-10 N-m (71-89 lb-in).
73. Tighten the left and right front strut upper mount nuts and tighten them to 46 N-m (34 lb-ft).
74. Fill the power steering pump remote fluid reservoir.
75. Connect the battery positive and negative cables.
76. Fill the transaxle to the proper level with Motorcraft MERCON® Multi-Purpose Automatic Transmission Fluid XT-2-QDX or MERCON® equivalent.
77. Check the operation of the transaxle.
78. Check the toe setting and adjust it if necessary.
