REMOVAL & INSTALLATION
See Figures 1, 2, 3 and 4
- Disconnect both battery cables, negative cable first.
- Remove the battery and battery tray. Remove the engine air cleaner assembly.
- Detach the transaxle harness and the Transmission Range (TR) sensor connectors.
- Remove the shift cable actuator fitting (cable retaining clip) and one retaining nut and disconnect the shift cable from the shift cable bracket on the transaxle.
- Disconnect the transaxle cooler lines.
- For the 3.0L OHV engines, remove the four upper transaxle-to-engine retaining bolts and one transaxle-to-engine stud.
- For the 3.0L and 3.4L (DOHC) engines, remove five transaxle-to-engine retaining bolts.
- Install two engine lifting brackets on the engine assembly.
- Install a suitable engine support device.
- Raise and safely support the vehicle.
- Loosen the transaxle oil pan retaining bolts and drain the transaxle fluid into a suitable container.
- Remove both front wheel and tire assemblies.
- Remove both halfshafts.
- Detach the four Heated Oxygen Sensor (HO 2 S) electrical connectors.
- Remove three bolts and seven nuts securing the converter Y-pipe assembly and remove from the vehicle.
- Detach the two starter motor connectors, then remove the starter.
- Remove one bolt and one stud securing the starter motor and remove the starter motor from the transaxle.
- For the OHV engine, remove one bolt and the transaxle housing cover.
- Support the rack and pinion assembly using wire attached to the strut and spring assembly to hold it in position. Remove two rack and pinion assembly retaining nuts from the subframe.
- Remove two lower control arm-to-ball joint retaining nuts and separate the lower control arms from the steering knuckles and ball joints.
- Remove the retaining nuts from the front engine support insulators (mounts) at the subframe.
- Remove the sway bar (stabilizer bar) link retaining nuts at each end of the sway bar and separate the links from the sway bar.
- Remove the engine and transaxle support insulator through-bolts from the subframe.
- Place a suitable transmission jack, using a suitable subframe adapter under the subframe and support the subframe.
- Remove the four subframe-to-body retaining bolts. Carefully lower the subframe and set aside.
- Place a suitable transmission jack using Adapter 014-00461 or equivalent, under the transaxle and support the transaxle assembly. Secure the transaxle to the transaxle adapter using a strap or chain.
- For the OHV engine, remove one lower engine-to-transaxle bolt.
- For the DOHC engine, remove the four lower engine-to-transaxle bolts.
- Remove the four flywheel-to-torque converter nuts.
- Remove three bolts and two nuts securing the rear engine support to the transaxle and remove the rear engine support.
- Remove one bolt from the right engine mount brace, then slowly lower the transaxle from the vehicle.
Flush the transaxle cooler lines thoroughly before installing the transaxle assembly.
- If removed, place the transaxle assembly on a suitable transmission jack using Adapter 014-00461 or equivalent. Secure the transaxle to the transaxle adapter using a strap or chain.
- Slowly raise the transaxle assembly into place. Align the torque converter studs with the appropriate holes in the flywheel and engage the transaxle housing to the engine dowel pins.
- Install one bolt in the right engine mount brace and tighten to 39-53 ft. lbs. (53-72 Nm).
- Install the rear engine support to the transaxle and install three bolts and two nuts. Tighten the bolts and nuts to 39-53 ft. lbs. (53-72 Nm).
- Install the four flywheel-to-torque converter nuts and tighten to 20-34 ft. lbs. (27-46 Nm).
- For the OHV engine, install one lower transaxle-to-engine bolt and tighten to 39-53 ft. lbs. (53-72 Nm).
- For the DOHC engine, install the four lower transaxle-to-engine bolts and tighten to 39-53 ft. lbs. (53-72 Nm).
- Place the subframe on High Lift Transmission Jack 014-00210 or equivalent, using a suitable subframe adapter and raise the subframe into position.
- Install the subframe insulators, if removed and loosely install four subframe-to-body bolts.
- Install a 3 / 4 inch (19mm) outside diameter pipe or similar tool into the front left subframe and body alignment holes and align the holes. Slightly tighten the front left subframe-to-body bolt.
- Repeat the subframe alignment procedure on the front right subframe and body alignment holes. Slightly tighten the right subframe-to-body bolt.
- Check the left alignment holes again and adjust if necessary.
- After the subframe alignment is complete, tighten all four subframe-to-body bolts to 57-76 ft. lbs. (77-103 Nm).
Install the remaining components in the reverse order of removal. Tighten the following:
Engine and transaxle support insulator-to-subframe bolts to 65-87 ft. lbs. (88-118 Nm)
- Connect both battery cables, negative cable last.
- If the transaxle is empty of transaxle fluid, add several quarts of MERCON or equivalent transaxle fluid to the transaxle.
- Start the engine and continue to fill the transaxle until the correct level is reached. Check for leaks and proper operation.
Whenever the vehicles subframe is removed or lowered, the wheel alignment should be checked.
- Check the front end alignment.
- Road test the vehicle and check the transaxle for proper operation.
There are no adjustments to the automatic transaxle in the Ford Taurus or Mercury Sable. The transaxle is electronically controlled by the PCM.