Special Tools (again according to Ford)
Support Bar, Engine 21 - 140
Adapter for 21-140, 21 - 140 - 01
Adapter for 21-140, 21 - 140 - 02
Adapter for 21-140, 21 - 140 - 03
Powertrain Fixture, 134-000250 (optional)
Powertrain Alignment Tool, T94P-6000-AH
Hi-Lift Transmission Jack, 014-000942
Sub Frame Alignment Pin Set, T94P-2100-AH
Installation
1. Position the transaxle to the engine using Hi - Lift Transmission Jack.
2. Install the eight bellhousing bolts.
3. Disconnect the holding strap and remove Hi - Lift Transmission Jack.
4. Note:
Do not tighten the bolts
Install subframe and subframe bolts.
5. Note:
Use new seals for the power steering lines.
Install the power steering line bracket bolt and connect the power steering lines on the steering gear.
6. Attach the shifter cables and bracket.
(1) Position the shifter cable bracket.
(2) Install the nuts.
(3) Attach the shifter cables.
Refer to corresponding illustration.
7. Note:
The power steering pressure hose must be correctly routed while positioning the subframe.
Note:
The intermediate shaft must be correctly aligned to the steering gear while positioning the subframe.
Tighten the subframe.
(1) Install the Subframe Alignment Pins.
(2) Align the subframe with the locating holes in the body.
(3) Install the subframe bolts working diagonally.
8. Install the rear roll restrictor bracket.
9. Install the rear roll restrictor.
(1) Install the bolts.
(2) Install the through bolt hand tight.
10. Install Powertrain Alignment Tool.
(1) Position Powertrain Alignment Tool.
(2) Install the bolts.
(3) Install the through bolt hand tight.
11. Install the intermediate shaft pinch bolt.
12. Attach the heated oxygen sensor electrical connector to the subframe.
Vehicles with air conditioning
13. Install the suction accumulator bolts to the subframe.
14. Install the bumper bracket.
15. Note:
LH side shown, RH side similar.
Install the radiator support brackets.
(1) Position the radiator support brackets.
(2) Install the bolts.
16. Install the secondary three - way catalytic converter.
(1) Position the secondary three - way catalytic converter.
(2) Install the nuts.
17. Install the Y line. For additional information, refer to �«Section 309-00�».
18. Install the radiator splash shield.
(1) Position the radiator splash shield.
(2) Install the bolts.
(3) Install the push pins.
19. Install a new snap-ring.
CAUTION:
To aviod to damage joints and boots, do not bent the inner halfshaft joint by more than 18 degrees, the outer one by not more than 45 degrees.
20. Note:
Do not damage the oil seal. Check that the snap - ring engages correctly.
Install the left - hand halfshaft.
CAUTION:
To aviod to damage joints and boots, do not bent the inner halfshaft joint by more than 18 degrees, the outer one by not more than 45 degrees.
21. Note:
Do not damage the oil seal.
Install the right - hand halfshaft.
22. CAUTION:
Do not damage boot and ABS - Sensor Ring
Connect the lower suspension arm ball joints and the stabilzer link rods.
(l) Attach the ABS wiring harness bracket to the suspension strut.
23. Install the lower wheel house covers (right - hand side shown).
24. Install the front wheels.
25. Note:
The fill level is 0-5 mm below the lower edge of the filler hole.
Check the transmission fluid level and fill up Transmission Fluid if necessary.
26. Lower the vehicle.
27. Install the four upper bellhousing bolts.
28. Install the LH transaxle support insulator stud.
29. Note:
Do not tigthen the bolts and nuts.
Install the LH transaxle support insulator.
(1) Install the nuts.
(2) Install the bolts.
(3) Install the LH transaxle support insulator.
30. Install the starter motor and bolts.
31. Connect the starter motor electrical connectors.
32. CAUTION:
Do not spill brake fluid onto painted surfaces.
Install the clutch slave cylinder hydraulic line.
33. Connect the fuel lines. For additional information, refer to �«Section 310-00�».
34. Bleed the clutch slave cylinder hydraulic system. For additional information, refer to �«Section 308-00�».
35. Connect the vehicle speed sensor (VSS) electrical connector and backup lamp switch electrical connector.
36. Loosen RH engine support insulator nuts.
(1) Disconnect the wire retainer.
(2) Loosen the nuts.
37. Note:
Use new self - locking nuts.
Tighten the LH transaxle support insulator.
38. Tighten the RH engine support insulator nuts.
(1) Tighten the nuts.
(2) Connect the wire retainer.
39. Install the air cleaner bracket and the starter motor bracket.
(1) Install the starter motor bracket.
(2) Install the air cleaner bracket.
40. Connect the ground cable.
41. Raise and support the vehicle. For additional information, refer to �«Section 100-02�».
42. Note:
Verify that rear roll restrictor is centered in the bracket and in perfect front to rear alignment before tightening the through bolt. As necessary, loosen the roll restrictor to subframe mounting bolts and reposition the roll restrictor.
Tighten the rear roll restrictor through bolt.
43. Remove Powertrain Alignment Tool.
(1) Remove the through bolt.
(2) Remove the bolts.
(3) Remove the Powertrain Alignment Tool.
44. Note:
Verify that the front roll restrictor is centered in the transaxle bracket and in perfect front to rear alignment before tightening the through bolt.
Install the front roll restrictor.
(1) Position the front roll restrictor.
(2) Install the nuts.
(3) Install the through bolt.
45. Lower the vehicle.
Refer to corresponding illustration.
46. Remove the Support Bar, Engine.
47. Connect the accelerator cable and speed control cables.
(1) Connect the accelerator and speed control cables.
(2) Connect the throttle cable.
48. Connect the accelerator and speed control cables (SVT Vehicles only).
(1) Connect the accelerator and speed control cables.
(2) Clip the cable into the bracket.
49. Connect the power steering reservoir hose.
(1) Position the power steering reservoir hose.
(2) Position the hose clamp.
(3) Install the power steering reservoir.
50. Install the water pump cover.
(l) Attach the engine coolant hose and install the bolts.
51. Remove the radiator supports.
52. Tighten the front wheels (right hand side shown).
(1) Wheel nut
(2) Driveshaft stub nut
53. Note:
Use an Allen wrench to stop the piston rod from turning.
Tighten the suspension strut locknuts (right - hand side shown).
54. Tighten the suspension strut locknuts with a torque wrench (right - hand side shown).
55. Install the battery tray. For additional information, refer to �«Section 414-01�».
56. Fill up and bleed the power steering system. For additional information, refer to �«Section 211-00�».
Again theres everything from the Ford service manual CD (minus pictures)
Well that removal and installation was a heck of a lot of editing. Didn't copy and paste well from the CD. I guess that gives a complete run down for this HOW-TO though. I'm sure there will be a lot of people that can benefit from this. Good luck with your endeavors guys!
