Installation

Special Tools:

General Equipment:

1. CAUTION: The torque converter is heavy. Install the special tool before raising the transaxle.

CAUTION: The torque converter must remain at the correct installation depth throughout the whole installation procedure.

NOTE: The torque converter studs must be aligned with the flywheel holes before any transaxle to engine bolts are installed.

Install the special tool (if not installed yet).

2. NOTE: The torque converter hub must engage fully in the oil pump drive gear.

Check the installation depth of the torque converter.
1 Lay a steel straightedge on the automatic transaxle flange.
2 Check the installation depth between the transaxle flange and the torque converter centering spigot for the correct clearance: 12 mm.
3 Apply a thin layer of High-temperature grease meeting Ford Specification ESD-M1C220-A or equivalent to the centering spigot bore on the torque converter.

3. Using the Hi-Lift Transmission Jack and the CD4E transaxle adaptor raise and position the transaxle into place.
^ Remove the special tool 307-346.

4. Install the transaxle to engine bolts.

5. NOTE: The special tool 307-346 (T94-7902A) must be removed.

Install the lower transaxle to engine bolts.

6. Install the torque converter nuts.
^ Install torque converter inspection cover.

CAUTION: To avoid to damage halfshaft joints and boots, do not bend the inner halfshaft joint by more than 18 degrees, the outer one by not more than 45 degrees.

7. NOTE: Do not damage the oil seal.

Install the right-hand halfshaft and intermediate shaft.

8. Install a new snap ring.

9. NOTE: Do not damage the oil seal. Check that the snap ring engages correctly.

Install the left-hand halfshaft.

10. Position and install the transaxle cooler upper line.

11. Position and install the transaxle lower line.

12. NOTE: Do not tighten the bolt.

Install the rear support insulator through bolt.

13. Install the sub-frame.

NOTE: Do not tighten the bolts.

^ Support the subframe using Rotunda Powertrain Lift. Place wooden block approximately 40 inches in length secured to lift under sub-frame.

14. Install the transaxle cooler line brackets, and bolt.

15. Install the power steering hoses to the subframe (one nut and two bolts).

16. Using the special tool, install the steering gear (two bolts) (left-hand side shown).

17. Install the steering gear heat shield.

18. Using the special tool, align the sub-frame and tighten the bolts.
1 Install the special tool.
2 Align the subframe with the locating holes in the body.
3 Install the subframe bolts working diagonally.

19. Remove the left-hand support insulator and install the special tool.
1 Install the special tool.
2 Install the bolts.
3 Install the through bolt.
20. Lower the vehicle.

21. Tighten the rear transaxle support bracket nuts.
22. Raise and support the vehicle.

23. Install the right-hand engine support insulator.

24. Tighten the rear support insulator through bolt.

25. Remove special tool 502-003 and install the left-hand support isolator.
1 Install the through bolt.
2 Install the bolts.

26. CAUTION: Do not damage boot and ABS sensor ring

Connect the lower suspension arm ball joints and the stabilizer link rods.
^ Attach the ABS wiring harness bracket to the suspension strut.

27. Install the front exhaust pipe and the rear three-way catalytic converter (TWC).
^ Install the gaskets.

28. Connect the front exhaust pipe and the rear TWC.
^ Install the gaskets.

29. Connect the heated oxygen sensor (HO2S) electrical connector.
^ Install the cable ties.

30. Install the suction accumulator bracket bolts (if A/C equipped).

31. Install the bumper brackets on both side (left-hand side shown).

32. Install the RH fender splash shield.

33. Install radiator splash shield.
^ Install the bolts and clips.
34. Lower the vehicle.

35. Install both front wheels (right hand side shown).

36. Disconnect the selector cable from the transaxle.
1 Selector lever selector cable
2 Bracket

37. NOTE: Install harness from transaxle.

Connect the vehicle speed sensor(VSS) electrical connector (shown from below).

38. Connect the turbine shaft speed sensor (TSS) (shown from below).
^ Clip the cable.

39. Install the upper bellhousing bolts (1999 MY four bolts).

40. Remove the special tools.

41. Connect the starter motor and install the starter motor bracket.

42. Install the water pump cover.
^ Attach the engine coolant hose and install the bolts.

43. Connect the electrical connections.
1 Ground cable
2 Automatic transaxle control - electrical connector
3 Transmission range (TR) switch - electrical connector
4 Wiring harness retaining clip

44. NOTE: Use an Allen key to stop the piston rod from turning.

Tighten the suspension strut locknuts (right-hand side shown).

45. Tighten the suspension strut locknuts with a torque wrench (right-hand side shown).

46. Remove the radiator supports.

47. Fill the transaxle with MERCON(r) multi-purpose automatic transmission fluid.

48. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.

Install the battery tray.
49. Fill and bleed the power steering system.