Material Specifications

All vehicles 

1. Secure the transaxle to a suitable transmission jack with a safety strap.
2. Prior to installing the transaxle, apply multi-purpose grease to the torque converter pilot hub.
   Fig 1: Locating Torque Converter Pilot Hub

   Courtesy of FORD MOTOR CO.
3. Position the transaxle to the back of the engine.
4. Install the 7 transaxle-to-engine bolts.
   • Tighten to 48 Nm (35 lb-ft).
   Fig 2: Locating Torque Converter Housing Bolts

   Courtesy of FORD MOTOR CO.
5. Connect the transmission fluid cooler hoses to the transmission cooler tubes.
   Fig 3: Locating Transmission Fluid Cooler Hoses Clamps

   Courtesy of FORD MOTOR CO.
6. Install 4 new torque converter nuts.
   • Tighten to 36 Nm (27 lb-ft).
   Fig 4: Locating Torque Converter Nut

   Courtesy of FORD MOTOR CO.
7. Position the inspection cover in place and install the 2 fasteners.
   Fig 5: Locating Inspection Cover And Fasteners

   Courtesy of FORD MOTOR CO.
8. Using the Powertrain Lift With Tilting Plate, raise the subframe into the installed position.
   Fig 6: Positioning Powertrain Lift With Tilting Plate Under Subframe Assembly

   Courtesy of FORD MOTOR CO.
NOTE: LH shown in the illustration, RH similar.
Fig 7: Locating Front Subframe Nut
Courtesy of FORD MOTOR CO.
9. Install the 2 front subframe nuts.
   • Tighten to 150 Nm (111 lb-ft).
NOTE: LH shown in the illustration, RH similar.
Fig 8: Locating Subframe Brackets Bolts
Courtesy of FORD MOTOR CO.
10. Position the subframe brackets and install the 4 bolts finger-tight.
NOTE: LH shown in the illustration, RH similar.
Fig 9: Locating Rear Subframe Nut
Courtesy of FORD MOTOR CO.
11. Install the 2 rear subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
NOTE: LH shown in the illustration, RH similar.
Fig 10: Locating Subframe Bracket-To-Body Bolts
Courtesy of FORD MOTOR CO.
12. Tighten the 4 subframe bracket-to-body bolts to 103 Nm (76 lb-ft).
NOTE: Use care when handling the steering gear to avoid unseating the steering gear/dash seal. If the steering gear/dash seal becomes unseated, water and foreign material may enter the passenger compartment and damage to the vehicle interior can occur.
Fig 11: Locating Steering Gear Mounting Bolts
Courtesy of FORD MOTOR CO.
13. Position the steering gear.
    1. Install the 3 steering gear mounting bolts.
    2. Tighten to 107 Nm (79 lb-ft).
14. Install the 3 power steering return line bolts.
    • Tighten to 9 Nm (80 lb-in).
    Fig 12: Locating Power Steering Return Line Bolt

    Courtesy of FORD MOTOR CO.
NOTE: LH shown in the illustration, RH similar.
Fig 13: Locating Stabilizer Bar Links Nut
Courtesy of FORD MOTOR CO.
15. Install the stabilizer bar links and nuts to the struts.
    • Tighten to 40 Nm (30 lb-ft).
NOTE: LH shown in the illustration, RH similar.
Fig 14: Locating Cotter Pins And Nuts Of Tie-Rod Ends
Courtesy of FORD MOTOR CO.
16. Install the tie-rod ends and nuts.
    • Tighten to 48 Nm (35 lb-ft).
    • Install new cotter pins.
NOTE: Front Wheel Drive (FWD) shown in the illustration, All-Wheel Drive (AWD) similar.
Fig 15: Locating Roll Restrictor Bracket Bolts
Courtesy of FORD MOTOR CO.
17. Install the 2 roll restrictor bracket bolts.
    • Tighten to 90 Nm (66 lb-ft).

    All-Wheel Drive (AWD) vehicles 

18. Install the Power Transfer Unit (PTU). For additional information, refer to TRANSFER CASE - POWER TRANSFER UNIT (PTU) -- FUSION & MILAN article.

    Front Wheel Drive (FWD) 

19. Install the exhaust flexible pipe. For additional information, refer to EXHAUST SYSTEM -- FUSION, MILAN & MKZ article.
20. Install the RH intermediate shaft. For additional information, refer to FRONT DRIVE HALFSHAFTS article.

    All vehicles 

21. Install the LH halfshaft. For additional information, refer to FRONT DRIVE HALFSHAFTS article.
22. Install the LH splash shield and the 6 pin-type retainers (4 shown in the illustration).
    Fig 16: Locating LH Splash Shield Pin-Type Retainers

    Courtesy of FORD MOTOR CO.
23. Position the LH fender splash shield and install the 4 screws.
    Fig 17: Locating LH Fender Splash Shield Screws

    Courtesy of FORD MOTOR CO.
24. Install the RH splash shield and the 6 pin-type retainers (4 shown in the illustration).
    Fig 18: Locating RH Splash Shield Pin-Type Retainers

    Courtesy of FORD MOTOR CO.
25. Position the RH fender splash shield and install the 4 screws.
    Fig 19: Locating RH Fender Splash Shield Screws

    Courtesy of FORD MOTOR CO.
26. Apply threadlock and sealer to the threads and install the transaxle support insulator bracket, the 2 nuts and the bolt.
    1. Tighten the bolt to 80 Nm (59 lb-ft).
    2. Tighten the nuts to 90 Nm (66 lb-ft).
    Fig 20: Identifying Transaxle Support Insulator Bracket Nuts And Bolt Tightening Sequence

    Courtesy of FORD MOTOR CO.
27. Using the Engine Support Bar, raise the transaxle. Apply threadlock and sealant to the threads and install the transaxle support insulator through bolt.
    • Tighten to 150 Nm (111 lb-ft).
    Fig 21: Locating Transaxle Support Insulator Through Bolt

    Courtesy of FORD MOTOR CO.
28. Remove the Engine Support Bar and Engine Spreader Bar.
    Fig 22: Installing Engine Support Bar And Engine Spreader Bar

    Courtesy of FORD MOTOR CO.
29. Remove the Engine Lift Eye from the LH cylinder head.
    Fig 23: Installing Engine Lift Eye On LH Cylinder Head

    Courtesy of FORD MOTOR CO.
30. Install the 4 upper transaxle-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
    Fig 24: Locating Upper Torque Converter Housing Bolts

    Courtesy of FORD MOTOR CO.
31. Position the 2 ground straps in place and install the 2 ground strap bolts.
    • Tighten to 12 Nm (106 lb-in).
    Fig 25: Locating Ground Strap Bolts

    Courtesy of FORD MOTOR CO.
32. Connect the wiring harness fasteners on the torque converter housing stud bolt and the starter motor.
    Fig 26: Locating Wiring Harness Fasteners And Torque Converter Housing Stud Bolt

    Courtesy of FORD MOTOR CO.
33. Connect the Transmission Control Module (TCM) electrical connector.
    Fig 27: Locating Transmission Control Module (TCM) Electrical Connector

    Courtesy of FORD MOTOR CO.
34. Position the selector lever cable bracket in place and install the 2 bolts and the nut.
    • Tighten to 12 Nm (106 lb-in).
    Fig 28: Locating Selector Lever Cable Bracket Bolts And Nut

    Courtesy of FORD MOTOR CO.
35. Connect the selector lever cable end.
    Fig 29: Locating Selector Lever Cable End

    Courtesy of FORD MOTOR CO.
36. Remove the transmission fluid fill plug.
    Fig 30: Locating Transmission Fluid Fill Plug

    Courtesy of FORD MOTOR CO.
37. Fill the transaxle with clean transmission fluid.
38. Install the transmission fluid fill plug.
    • Tighten to 39 Nm (29 lb-ft).
    Fig 31: Locating Transmission Fluid Fill Plug

    Courtesy of FORD MOTOR CO.
39. Install the upper intake manifold. For additional information, refer to ENGINE MECHANICAL - 3.5L -- FUSION & MKZ article.
40. Install the starter. For additional information, refer to STARTING SYSTEM article.
41. Install the Air Cleaner (ACL) and outlet tube. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING - 3.5L -- FUSION & MKZ article.
42. Remove the transmission fluid level indicator and make sure that the transaxle has transmission fluid in it.
43. With the transaxle in PARK, the vehicle on a level surface, the engine at idle (680-780 rpm) and foot pressed on the brake, move the selector lever through each gear and allow engagement of each gear. Place the selector lever back in the PARK position.
44. Wipe the transmission fluid level indicator cap and remove the transmission fluid level indicator.
45. Wipe the transmission fluid level indicator with a clean cloth.
NOTE: In order to get an accurate transmission fluid level reading the vehicle should be on a level surface. Idle the engine to reach the normal operating temperature. Using the scan tool, verify that the transaxle is at normal operating temperature 60°C-70°C (140°F-158°F), prior to adjusting the transmission fluid level.
Fig 32: Locating Transmission Fluid Level Indicator Cap
Courtesy of FORD MOTOR CO.
46. If transmission fluid needs to be added, add transmission fluid in 0.25L (1/2 pt) increments through the transmission fluid fill plug located on the top of the transaxle near the transmission fluid level indicator. Do not overfill the transmission fluid. Install the transmission fluid level indicator back in the transmission fluid filler tube until it is fully seated, then remove the indicator. The transmission fluid level should be at the upper most mark on the transmission fluid level indicator. Only fill to the upper most mark on the transmission fluid level indicator. Do not overfill. Damage to the transaxle will occur.
NOTE: The correct transmission fluid level at normal operating temperature of 60°C-70°C (140°F-158°F) is between the top 2 marks on the transmission fluid level indicator.
Fig 33: Locating Marks On Transmission Fluid Level Indicator
Courtesy of FORD MOTOR CO.
47. Fill the transaxle to the correct transmission fluid level.
NOTE: The correct transmission fluid level at cold operating temperature of 15°C-25°C (59°F-77°F) is at the bottom mark on the transmission fluid level indicator.
Fig 34: Locating Mark On Transmission Fluid Level Indicator
Courtesy of FORD MOTOR CO.
48. If the Transmission Fluid Temperature (TFT) is low, fill the transaxle with transmission fluid to the cold range on the transmission fluid level indicator. Recheck the transmission fluid level when the transaxle has reached the normal operating temperature.
49. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.