2004 Ford Freestar BaseFACTORY OEM SERVICE PROCEDURE

Automatic Transmission: Installation: Transaxle

Special Tool(s) 

Fig 1: Identifying Special Tool
G03245104Courtesy of FORD MOTOR CO.
MATERIAL

Item Specification
MERCON® V Automatic Transmission Fluid XT-5-QM MERCON® V
Multi-Purpose Grease D0AZ-19584-AA ESB-M1C93-B
  1. Secure the transaxle on a high lift transmission jack. Apply multi-purpose grease to the torque converter pilot hub.
    Fig 2: Applying Multi-Purpose Grease To Torque Converter Pilot Hub
    G03245105Courtesy of FORD MOTOR CO.
  2. Install the shift cable bracket and bolts.
    • Tighten to 23 Nm (17 lb-ft).
    Fig 3: Installing Shift Cable Bracket And Bolts
    G03245106Courtesy of FORD MOTOR CO.
  3. If not previously installed, install the heat shield.
    Fig 4: Installing Heat Shield
    G03245107Courtesy of FORD MOTOR CO.
  4. If not previously installed, install the rear engine support bracket.
    • Tighten to 62 Nm (46 lb-ft).
    Fig 5: Installing Rear Engine Support Bracket
    G03245108Courtesy of FORD MOTOR CO.
  5. Verify the position of the special tools.
    Fig 6: Verifying Position Of Special Tools
    G03245109Courtesy of FORD MOTOR CO.
  6. Position the transaxle to the back of the engine.
  7. Position the transaxle to the engine assembly, and install the transaxle retaining bolts.
    • Tighten to 47 Nm (35 lb-ft).
    Fig 7: Installing Transaxle Retaining Bolts
    G03245110Courtesy of FORD MOTOR CO.
  8. Install the oil pan-to-transaxle case bolt.
    • Tighten to 62 Nm (46 lb-ft).
    Fig 8: Installing Oil Pan-To-Transaxle Case Bolt
    G03245111Courtesy of FORD MOTOR CO.
  9. Install the oil pan-to-transaxle case bolt.
    • Tighten to 62 Nm (46 lb-ft).
    Fig 9: Installing Oil Pan-To-Transaxle Case Bolt
    G03245112Courtesy of FORD MOTOR CO.
  10. Install the front lower retaining bolt.
    • Tighten to 62 Nm (46 lb-ft).
    Fig 10: Installing Front Lower Retaining Bolt
    G03245113Courtesy of FORD MOTOR CO.
  11. Install the rear lower retaining bolt.
    • Tighten to 62 Nm (46 lb-ft).
    Fig 11: Installing Rear Lower Retaining Bolt
    G03245114Courtesy of FORD MOTOR CO.
  12. Remove the high-lift transmission jack.
  13. Connect the turbine shaft speed (TSS) sensor electrical connector.
    Fig 12: Connecting Turbine Shaft Speed (TSS) Sensor Electrical Connector
    G03245115Courtesy of FORD MOTOR CO.
  14. Connect the output shaft speed (OSS) sensor electrical connector.
    Fig 13: Connecting Output Shaft Speed (OSS) Sensor Electrical Connector
    G03245116Courtesy of FORD MOTOR CO.
  15. Install the RH halfshaft.
    Fig 14: Installing RH Halfshaft
    G03245117Courtesy of FORD MOTOR CO.
  16. Install the LH halfshaft.
    Fig 15: Installing LH Halfshaft
    G03245118Courtesy of FORD MOTOR CO.
  17. NOTE: Locate and align the orange dot adjacent to the stud on the torque converter with the orange dot on the flexplate.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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