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Home >> Ford >> 2011 >> Fusion SEL, 2.5 A >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transaxle - 6F35 - Disassembly, Disassembly And Assembly Of Subassemblies, Assembly, Installation >> Installation >> Transaxle - 2.5L >> Installation

Transaxle - 2.5L: Installation

NOTE: If the transaxle was overhauled, or if installing a new transaxle and the transmission fluid cooler has not been flushed, flush the transmission fluid cooler at this time. For additional information, refer to TRANSMISSION FLUID COOLER BACKFLUSHING AND CLEANING in this service information. Clean the transaxle-mounted transmission fluid cooler tubes by hand.
  1. Install the transmission fluid cooler tube bracket and the 2 nuts.
    • Tighten to 9 Nm (80 lb-in).
      Fig 1: Locating Transmission Fluid Cooler Tube Bracket Nuts
      G07783537Courtesy of FORD MOTOR CO.
  2. Install the transmission fluid cooler tubes in the transaxle by inserting the tube into the fitting until a click is heard/felt. Pull back to confirm connection is secure and position them in the retainer mounted on the main control cover studbolts.
    Fig 2: Locating Transmission Fluid Cooler Tubes On Transaxle
    G07783538Courtesy of FORD MOTOR CO.
  3. Install the 2 secondary latches.
    Fig 3: Locating Secondary Latches
    G07783539Courtesy of FORD MOTOR CO.
  4. Position the transmission fluid cooler tubes in the retainers and close the 2 transmission fluid cooler tube retainers.
    Fig 4: Positioning Transmission Fluid Cooler Tubes
    G07783540Courtesy of FORD MOTOR CO.
  5. Inspect the O-ring seal on the transaxle filler tube for damage and install a new O-ring if needed. Lubricate the O-ring seal with clean automatic transmission fluid.
    Fig 5: Locating Transaxle Filler Tube O-Ring Seal
    G07783541Courtesy of FORD MOTOR CO.
  6. Position the transmission fluid cooler tube in place and install the vent tube.
    Fig 6: Locating Transmission Fluid Filler Tube And Transaxle Vent Tube
    G07783542Courtesy of FORD MOTOR CO.
  7. Install the transmission fluid filler tube nut.
    • Tighten to 11 Nm (97 lb-in).
      Fig 7: Locating Transmission Fluid Filler Tube Nut
      G07783543Courtesy of FORD MOTOR CO.
  8. Install the transmission fluid level indicator.
    Fig 8: Locating Transmission Fluid Level Indicator
    G07783544Courtesy of FORD MOTOR CO.
  9. Secure the transaxle to a suitable transmission jack with a safety strap.
  10. Prior to installing the transaxle, apply multi-purpose grease to the torque converter pilot hub.
    Fig 9: Locating Torque Converter Pilot Hub
    G07783545Courtesy of FORD MOTOR CO.
  11. Position the transaxle into the engine compartment.
    Fig 10: Identifying Transaxle
    G07783546Courtesy of FORD MOTOR CO.
  12. Remove the Torque Converter Retainer.
    Fig 11: Identifying Torque Converter Retainer
    G07783547Courtesy of FORD MOTOR CO.
    13. NOTE: Make sure that the dowel pins are installed in the engine block prior to installing the transaxle.
  13. Position the transaxle on the dowel pins.
    14. NOTE: Note the location of the different length bolts.
  14. Install the 4 front torque converter housing bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 12: Locating Front Torque Converter Housing Bolts
      G07783548Courtesy of FORD MOTOR CO.
  15. Install the 3 rear torque converter housing bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 13: Locating Rear Torque Converter Housing Bolts
      G07783549Courtesy of FORD MOTOR CO.
  16. Remove the transmission jack.
  17. Connect the transmission fluid cooler tubes by inserting the tube into the fitting until a click is heard/felt. Pull back to confirm that the connection is secure.
    Fig 14: Locating Transmission Fluid Cooler Tube Fittings
    G07783550Courtesy of FORD MOTOR CO.
  18. Install the transmission fluid cooler tube secondary latches.
    Fig 15: Locating Transmission Fluid Cooler Tube Secondary Latches
    G07783551Courtesy of FORD MOTOR CO.
  19. Connect the Turbine Shaft Speed (TSS) electrical connector.
    Fig 16: Locating Turbine Shaft Speed (TSS) Sensor Electrical Connector
    G07783552Courtesy of FORD MOTOR CO.
  20. Connect the transaxle main electrical connector.
    Fig 17: Locating Transaxle Electrical Connector
    G07783553Courtesy of FORD MOTOR CO.
    21. NOTE: Rotate the engine in a clockwise direction only or engine damage will occur.
  21. Install 4 new torque converter nuts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 18: Locating Torque Converter Nuts
      G07783554Courtesy of FORD MOTOR CO.
  22. Install the rubber insulator in the bellhousing.
    Fig 19: Locating Bellhousing Rubber Insulator
    G07783555Courtesy of FORD MOTOR CO.
  23. Install the starter motor. For additional information, refer to STARTING SYSTEM article.
  24. Apply threadlock and sealer to the threads and install the transaxle support insulator bracket, the 3 nuts and the bolt.
    • Tighten to 63 Nm (46 lb-ft).
      Fig 20: Locating Transaxle Support Insulator Bracket And Fasteners
      G07783556Courtesy of FORD MOTOR CO.
  25. Lift the transaxle until the transaxle support insulator bracket is aligned with the transaxle support insulator, apply threadlock and sealant to the threads and install the through bolt.
    • Tighten to 150 Nm (111 lb-ft).
      Fig 21: Locating Transaxle Support Insulator Through Bolt
      G07783557Courtesy of FORD MOTOR CO.
  26. Remove the Engine Support Bar.
    Fig 22: Supporting Engine Using Engine Support Bar
    G07783558Courtesy of FORD MOTOR CO.
  27. Place the subframe assembly on the Powertrain Lift With Tilting Plate and raise the subframe into the installed position.
    Fig 23: Positioning Powertrain Lift With Tilting Plate Under Subframe Assembly
    G07783559Courtesy of FORD MOTOR CO.
    28. NOTE: LH shown in illustration, RH similar.
  28. Install the front subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
      Fig 24: Locating Front Subframe Nut
      G07783560Courtesy of FORD MOTOR CO.
    29. NOTE: LH shown in illustration, RH similar.
    Fig 25: Locating Subframe Bracket Bolts
    G07783561Courtesy of FORD MOTOR CO.
  29. Position the subframe brackets and install the bolts finger-tight.
    30. NOTE: LH shown in illustration, RH similar.
  30. Install the subframe nuts.
    • Tighten to 150 Nm (111 lb-ft).
      Fig 26: Locating Subframe Nut
      G07783562Courtesy of FORD MOTOR CO.
    31. NOTE: LH shown in illustration, RH similar.
    Fig 27: Locating Subframe Bracket-To-Body Bolts
    G07783563Courtesy of FORD MOTOR CO.
  31. Tighten the subframe bracket-to-body bolts to 103 Nm (76 lb-ft).
    32. NOTE: LH shown in illustration, RH similar.
  32. Install the sway bar links and nuts to the struts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 28: Locating Sway Bar Link Nut
      G07783564Courtesy of FORD MOTOR CO.
  33. Install the Electronic Power Assist Steering (EPAS) system wiring harness ground and the bolt behind the RH splash shield.
    • Tighten to 12 Nm (106 lb-in).
      Fig 29: Locating EPAS System Wiring Harness Ground And Bolt
      G07783565Courtesy of FORD MOTOR CO.
  34. Attach the EPAS system wiring harness pin-type retainer to the subframe under the LH fender splash shield.
    Fig 30: Locating EPAS System Wiring Harness Pin-Type Retainer
    G07783566Courtesy of FORD MOTOR CO.
  35. Attach the 2 EPAS system wiring harness pin-type retainers to the subframe.
    Fig 31: Locating EPAS System Wiring Harness Pin-Type Retainers
    G07783567Courtesy of FORD MOTOR CO.
  36. Connect the 2 in-line EPAS system electrical connectors at the front of the subframe.
    Fig 32: Locating In-Line Electronic Power Assist Steering System Electrical Connectors
    G07783568Courtesy of FORD MOTOR CO.
  37. Install the LH halfshaft and the intermediate shaft. For additional information, refer to FRONT DRIVE HALFSHAFTS article.
  38. Install the LH splash shield and the 6 pin-type retainers (4 shown in illustration).
    Fig 33: Locating LH Splash Shield Pin-Type Retainers
    G07783569Courtesy of FORD MOTOR CO.
  39. Position the LH fender splash shield and install the 4 screws.
    Fig 34: Locating LH Fender Splash Shield Screws
    G07783570Courtesy of FORD MOTOR CO.
  40. Install the RH splash shield and the 6 pin-type retainers (4 shown in illustration).
    Fig 35: Locating RH Splash With Pin-Type Retainers
    G07783571Courtesy of FORD MOTOR CO.
  41. Position the RH fender splash shield and install the 4 screws.
    Fig 36: Locating RH Fender Splash Shield Screws
    G07783572Courtesy of FORD MOTOR CO.
  42. Install the 2 roll restrictor bracket bolts.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 37: Locating Roll Restrictor Bracket Bolts
      G07783573Courtesy of FORD MOTOR CO.
  43. If equipped, install the 7 screws and the underbody cover.
    Fig 38: Locating Underbody Cover Screws
    G07783574Courtesy of FORD MOTOR CO.
    44. NOTE: The steering gear/dash seal must be fully seated in the steering valve tower groove before the retaining clips are fully engaged into the body. If the steering gear/dash seal is not seated to the steering gear valve tower groove and the clips are not fully engaged to the body, water and foreign material may enter the passenger compartment and damage the vehicle interior can occur.
  44. Install the steering gear/dash seal.
    • Apply hand force to the center of the seal, install the steering gear/dash seal onto the steering gear valve tower until the seal is fully seated in the valve tower groove. Install the steering gear/dash seal until the retaining clips are fully engaged into the body.
      Fig 39: Locating Steering Gear/Dash Seal Off Clips
      G07783575Courtesy of FORD MOTOR CO.
  45. Install the steering column shaft onto the steering gear and install a new bolt.
    • Tighten to 20 Nm (177 lb-in).
      Fig 40: Locating Steering Column Shaft Bolt
      G07783576Courtesy of FORD MOTOR CO.
  46. Install the steering joint cover and the 2 nuts.
    Fig 41: Locating Steering Joint Cover And Nut
    G07783577Courtesy of FORD MOTOR CO.
  47. Install the 3 top torque converter housing bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 42: Locating Torque Converter Housing Bolts
      G07783578Courtesy of FORD MOTOR CO.
  48. Connect the wiring harness retainers to the main control cover studbolts.
    Fig 43: Locating Transaxle Electrical Wiring Harness Retainers
    G07783579Courtesy of FORD MOTOR CO.
  49. Position the selector lever cable bracket in place and install the 2 nuts.
    • Tighten to 12 Nm (106 lb-in).
      Fig 44: Locating Selector Lever Cable Bracket Nuts
      G07783580Courtesy of FORD MOTOR CO.
  50. Connect the selector lever cable end to the manual control lever with the manual control lever and selector lever in DRIVE. Check selector lever cable adjustment. For additional information, refer to AUTOMATIC TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS - AISIN AW21/6F35 FUSION, MILAN & MKZ (EXCEPT HYBRID)--> article.
    Fig 45: Locating Selector Lever Cable End Of Manual Control Lever
    G07783581Courtesy of FORD MOTOR CO.
  51. Install the battery and battery tray. For additional information, refer to BATTERY, MOUNTING & CABLES FUSION, MILAN & MKZ--> article.
  52. Install the Air Cleaner (ACL) and the outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING - 2.5L FUSION & MILAN (EXCEPT HYBRID)--> article.
  53. Fill the transaxle with clean transmission fluid.
    Fig 46: Locating Transmission Fluid Level Indicator
    G07783582Courtesy of FORD MOTOR CO.
  54. Start the engine and move the range selector lever into each gear position.
  55. Using the scan tool with the engine running, check and make sure that the transmission is at normal operating temperature 85-93°C (185-200°F). Check and adjust the transmission fluid level and check for any leaks. If transmission fluid is needed, add transmission fluid in increments of 0.24L (0.5 pt) until the correct level is achieved.
  56. If a replacement transaxle assembly is being installed or a new solenoid body is installed, the PCM will have to be reflashed with a new solenoid body strategy and identification data file. For additional information, refer to SOLENOID BODY STRATEGY in this service information.
  57. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.
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