Mercury Cougar 2000-2002

Transaxle Removal & Installation

Print

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Secure the radiator and fan shroud to the radiator support.
  4.  
  5. Loosen the left and right upper strut mounting nuts 5 turns.
  6.  
  7. Attach an engine support fixture to the engine lifting eyes.
  8.  
  9. Drain the transaxle fluid.

    Click image to see an enlarged view

    Fig. Transaxle drain plug location

  10.  
  11. Remove or disconnect the following:

    Battery
     
    Air cleaner assembly and mounting bracket
     
    Shift cable and bracket
     
    Transaxle control wiring harness connector
     
    Transaxle range sensor
     
    Rear transaxle support insulator
     
    Oil dipstick tube and exhaust manifold heat shield (2.0L engine)
     
    Water pump pulley shield (2.5L engine)
     
    Steering column pinch bolt
     
    Front wheels
     
    Left, right and center splash shields
     
    Lower ball joints
     
    Outer tie rod ends
     
    Stabilizer bar links
     
    Left and right engine support insulators
     
    Power steering oil cooler hoses
     
    Bumper cover braces
     
    Radiator air deflector
     
    Lower radiator supports
     
    Exhaust system
     
    A/C accumulator mounting bolts
     
    Transaxle cooler lines and bracket
     
    Power steering hoses. Lower the sub-frame for access.
     
    Sub-frame
     
    Turbine Speed (TSS) sensor connector

    Click image to see an enlarged view

    Fig. TSS sensor location

     
    Halfshafts and intermediate shaft
     
    Vehicle Speed (VSS) sensor connector
     
    Torque converter nuts
     
    Starter
     
    Front engine support insulator bracket
     

  12.  
  13. Lower the powertrain until the transaxle is level with the left frame member.
  14.  
  15. Support the transaxle on a transmission jack.
  16.  
  17. Remove or disconnect the following:
    NOTE
    Use care when removing the transaxle to prevent the torque converter from falling out.



    Transaxle flange bolts
     
    Transaxle from the engine
     
    Transaxle
     

  18.  

To install:

Click image to see an enlarged view

Fig. Be sure that the torque converter is properly seated in the transaxle


NOTE
Replace all snaprings, split pins and self-locking nuts.

  1. Install or connect the following:
    NOTE
    The left and right support insulators must be aligned in the middle of the support insulator brackets.



    Transaxle and tighten the flange bolts to 41-50 ft. lbs. (55-68 Nm)
     
    Torque converter and tighten the nuts to 23-39 ft. lbs. (31-53 Nm)
     
    TSS connector
     
    Sub-frame. Attach the power steering hoses before installing the sub-frame bolts.
     
    Special tool Sub-frame Alignment Pin Set T95P-2100-AH and the sub-frame bolts. Tighten the sub-frame bolts to 81-110 ft. lbs. (110-150 Nm). Remove the alignment pins.
     
    A/C accumulator bolts
     
    Power steering oil cooler lines
     
    Special tool Powertrain Alignment Gauge T94P-6000-AH in place of the left engine support insulator. Tighten the 2 retaining bolts to 20 ft. lbs. (27 Nm) and snug the through-bolt.
     



    Right engine support insulator. Tighten the 2 sub-frame retaining bolts to 30-41 ft. lbs. (41-55 Nm) and the through-bolt to 75-102 ft. lbs. (103-137 Nm).
     
    Rear engine support insulator and tighten the nuts to 61 ft. lbs. (83 Nm)
     
    Front engine support insulator and tighten the nuts to 61 ft. lbs. (83 Nm)
     

  2.  
  3. Remove the Powertrain Alignment Tool and install the left engine support insulator. Tighten the center bolt to 88 ft. lbs. (120 Nm), and the mounting bolts to 35 ft. lbs. (48 Nm).

    Transaxle oil cooler lines
     
    Starter and tighten the bolts to 43-58 ft. lbs. (59-79 Nm) for the 2.5L engine or 15-20 ft. lbs. (20-27 Nm) for the 2.0L engine
     
    VSS sensor connector
     
    Halfshafts and intermediate shaft
     
    Exhaust system
     
    Lower radiator supports
     
    Radiator air deflector
     
    Bumper cover braces
     
    Power steering oil cooler hoses
     
    Left and right engine support insulators
     
    Stabilizer bar links and tighten the nuts to 35-48 ft. lbs. (47-65 Nm)
     
    Outer tie rod ends and tighten the nuts to 23-35 ft. lbs. (31-47 Nm)
     
    Lower ball joints and tighten the pinch bolt to 61 ft. lbs. (83 Nm)
     
    Left, right and center splash shields
     
    Front wheels and tighten the lug nuts to 63 ft. lbs. (86 Nm)
     
    Steering column pinch bolt and tighten the bolt to 15-20 ft. lbs. (20-27 Nm)
     
    Water pump pulley shield (2.5L engine)
     
    Oil dipstick tube and exhaust manifold heat shield (2.0L engine)
     
    Transaxle range sensor
     
    Transaxle control wiring harness connector
     
    Shift cable and bracket
     
    Air cleaner assembly and mounting bracket
     
    Battery
     

  4.  
  5. Tighten the upper strut mount nuts to 34 ft. lbs. (46 Nm).
  6.  
  7. Fill the transaxle.
  8.  
  9. Check for leaks and proper operation.
    NOTE
    Whenever the vehicle sub-frame is removed or lowered, the wheel alignment should be checked.



    Click image to see an enlarged view

    Fig. To properly align the sub-frame, install Sub-frame Alignment Pin Set T95P-2100-AH-manual and automatic transaxles

  10.  

 
AutoZone Logo