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Section 4 (Manual Transaxle (IB5)): Installation: Transaxle: Installation

WARNING: This page is about a different variant/trim than selected.
  1. Install the transaxle.
  2. Install the 4 lower clutch housing-to-engine bolts (3 shown in illustration).
    • Tighten to 48 Nm (35 lb-ft).
    Fig 1: Locating Lower Clutch Housing-To-Engine Bolts
    G06938077Courtesy of FORD MOTOR CO.
  3. Using the special tools, lower the transaxle.
    Fig 2: Lowering Transaxle Using Special Tools
    G06939368Courtesy of FORD MOTOR CO.
  4. Install the transaxle support insulator, the 2 transaxle support insulator bolts and the 2 nuts.
    • Tighten the 2 bolts to 90 Nm (66 lb-ft).
    • Tighten the 2 nuts to 125 Nm (92 lb-ft).
    Fig 3: Locating Transaxle Support Insulator Bolts And Nuts
    G06937109Courtesy of FORD MOTOR CO.
  5. Install the ground wire and bolt onto the transaxle.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 4: Locating Ground Wire Bolt
    G06938074Courtesy of FORD MOTOR CO.
  6. Attach the clutch hydraulic hose to the transaxle retainer.
    Fig 5: Locating Clutch Hydraulic Hose
    G06937152Courtesy of FORD MOTOR CO.
    7. WARNING: Carefully read cautionary information on product label. For emergency medical information seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury.
    NOTE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.
    Fig 6: Locating Clutch Hydraulic Hose Clip
    G06937151Courtesy of FORD MOTOR CO.
  7. Install the clutch hydraulic hose onto the transaxle and install the clip.
  8. Install the 2 LH clutch housing-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
    Fig 7: Locating LH Clutch Housing-To-Engine Bolts
    G06938064Courtesy of FORD MOTOR CO.
    9. NOTE: The roll restrictor bolts are different lengths, make sure the roll restrictor bolts are in the correct location using the marks made during removal.
    Fig 8: Locating Roll Restrictor, Bolts And Bracket
    G06938063Courtesy of FORD MOTOR CO.
  9. Install the roll restrictor bracket, roll restrictor and the roll restrictor bolts.

    Loosely install the 2 roll restrictor bolts and the 2 roll restrictor bracket bolts at this time.

    • Only tighten the top 2 roll restrictor bracket bolts.
      • Tighten the to 48 Nm (35 lb-ft).
  10. Tighten the roll restrictor bolts.
    1. Tighten the roll restrictor bolt to 70 Nm (52 lb-ft).
    2. Tighten the roll restrictor-to-transaxle bracket bolt to 70 Nm (52 lb-ft).
      Fig 9: Identifying Roll Restrictor Bolts
      G06937220Courtesy of FORD MOTOR CO.
  11. Attach the Heated Oxygen Sensor (HO2S) bracket to the transaxle and install the HO2S  bracket nut.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 10: Locating Heated Oxygen Sensor Bracket And Nut
    G06938062Courtesy of FORD MOTOR CO.
  12. Using a new exhaust flange gasket and nuts, connect the exhaust flange to the exhaust.
    • Tighten to 48 Nm (35 lb-ft).
    Fig 11: Locating Exhaust Flange Nuts And Exhaust Flange Gasket
    G06939154Courtesy of FORD MOTOR CO.
  13. Install the LH halfshaft into the transaxle.
  14. Install the LH ball joint into the knuckle.
  15. Install the new LH ball joint bolt and nut.
    • Tighten to 48 Nm (35 lb-ft).
    Fig 12: Locating LH Ball Joint Nut And Bolt
    G06939367Courtesy of FORD MOTOR CO.
  16. Install the brake hose retainer and bolt on the LH strut.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 13: Locating Brake Hose Retainer Bolt And Retainer
    G06939366Courtesy of FORD MOTOR CO.
  17. Install the RH intermediate shaft assembly into the transaxle.
  18. Install the new bearing retainer strap and shield (if equipped).
    • Install the strap on the studs.
    • Position the shield (if equipped) on the studs.
    Fig 14: Installing Bearing Retainer Strap And Shield
    G07980200Courtesy of FORD MOTOR CO.
    NOTE: Install the bearing retainer strap on the bracket studs before the shield, and tighten the nuts evenly in stages (alternating from top to bottom) or incorrect bearing clampload may occur causing component damage.
  19. Install the new bearing retainer strap nuts.
    • Tighten to 6 Nm (53 lb-in).
    • Tighten to 6 Nm (53 lb-in).
    • Tighten to 25 Nm (18 lb-ft).
    • Tighten to 25 Nm (18 lb-ft).
    Fig 15: Identifying Bearing Retainer Strap Nuts Tightening Sequence
    G07980201Courtesy of FORD MOTOR CO.
  20. Install the RH ball joint into the knuckle.
  21. Install the new RH ball joint bolt and nut.
    • Tighten to 48 Nm (35 lb-ft).
    Fig 16: Locating RH Ball Joint Nut And Bolt
    G06939364Courtesy of FORD MOTOR CO.
  22. Install the brake hose retainer and bolt on the RH strut.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 17: Locating Brake Hose Retainer Bolt
    G06939363Courtesy of FORD MOTOR CO.
  23. Install the front wheels. For additional information, refer to WHEELS AND TIRES .
  24. Install the 2 top clutch housing-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
    Fig 18: Locating Top Clutch Housing-To-Engine Bolts
    G06938057Courtesy of FORD MOTOR CO.
  25. Install the 4 clutch housing-to-engine bolts (3 shown in illustration).
    • Tighten to 48 Nm (35 lb-ft).
    Fig 19: Locating Clutch Housing-To-Engine Bolts
    G06938056Courtesy of FORD MOTOR CO.
  26. Install the transaxle vent hose on the cooling fan housing.
    Fig 20: Locating Transaxle Vent Hose Of Cooling Fan Housing
    G06939351Courtesy of FORD MOTOR CO.
  27. Attach the transaxle vent hose to the hose retainer.
    Fig 21: Locating Transaxle Vent Hose
    G06938054Courtesy of FORD MOTOR CO.
  28. Connect the reverse light switch electrical connector.
    Fig 22: Locating Reverse Light Switch Electrical Connector
    G06938195Courtesy of FORD MOTOR CO.
  29. Install the wiring harness bracket and wiring harness bracket bolt to the transaxle.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 23: Locating Wiring Harness Bracket Bolt Of Transaxle
    G06938052Courtesy of FORD MOTOR CO.
  30. Install the battery tray bracket and the 3 battery tray bracket nuts.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 24: Locating Battery Tray Bracket And Nuts
    G06937139Courtesy of FORD MOTOR CO.
  31. Attach the wiring harness to the battery tray bracket.
    Fig 25: Locating Battery Tray Bracket Wiring Harness Tie Straps
    G06939412Courtesy of FORD MOTOR CO.
  32. Install the battery tray and 3 battery tray bolts.
    • Tighten to 10 Nm (89 lb-in).
    Fig 26: Locating Battery Tray Bolts
    G06937082Courtesy of FORD MOTOR CO.
  33. Connect the 3 PCM electrical connectors.
    Fig 27: Locating PCM Electrical Connectors
    G06937081Courtesy of FORD MOTOR CO.
  34. Install the PCM cover and the PCM cover bolt.
    • Tighten to 6 Nm (53 lb-in).
    Fig 28: Locating PCM Cover And Bolt
    G06937080Courtesy of FORD MOTOR CO.
  35. Install the cowl assembly. For additional information, refer to FRONT END BODY PANELS .
  36. Install the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  37. Fill the transaxle with transmission fluid. For additional information, refer to Transaxle Draining and Filling .
  38. Bleed the clutch hydraulic system. For additional information, refer to MANUAL TRANSAXLE/TRANSMISSION AND CLUTCH - GENERAL INFORMATION .
  39. Adjust the gearshift cables. For additional information, refer to MANUAL TRANSAXLE/TRANSMISSION AND CLUTCH - GENERAL INFORMATION .
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