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HOMESERVICE MANUALSFORD2004MUSTANG BASE, 2D COUPE, 3.9 6, AUTOMATICREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1205 (ENGINE - 2.3L - (EXCEPT HYBRID))INSTALLATIONENGINE - AUTOMATIC TRANSAXLE
2004 Ford Mustang Base, 2D Coupe, 3.9 6, Automatic

Engine - Automatic Transaxle

2004 Ford Mustang Base, 2D Coupe, 3.9 6, AutomaticSECTION Engine - Automatic Transaxle
WARNING: This page is about a different car, the 2006 Mercury Mariner and 2006 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL(S)

G04618339Courtesy of FORD MOTOR CO.
 Heavy Duty Floor Crane
014-00071 or equivalent
G04618340Courtesy of FORD MOTOR CO.
 Spreader Bar
303-D089 (D93P-6001-A3) or equivalent
G04618341Courtesy of FORD MOTOR CO.
 Powertrain Lift
014-00765
G04618342Courtesy of FORD MOTOR CO.
 Universal Adapter Brackets
014-0001
Lifting Bracket Set, Engine
303-D095 (D94L-6001-A) or equivalent
MATERIALS

Item Specification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil
XO-5W20-QSP (in Canada Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12) or equivalent		 WSS-M2C930-A
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury.

    All vehicles 

  1. Using the engine crane and spreader bar, position the engine and transaxle together. Install the 6 transaxle-to-engine bolts.
    • Tighten to 48 N.m (35 lb-ft).
  2. Install new torque converter nuts.
    • Tighten to 35 N.m (26 lb-ft).
      Fig 1: Locating Torque Converter Nut
      G03897896Courtesy of FORD MOTOR CO.
  3. Install the starter motor isolator.
    Fig 2: Identifying Starter Motor Isolator
    G03897895Courtesy of FORD MOTOR CO.
  4. Using the engine crane and spreader bar, position the engine and transaxle onto the lift table.
  5. Using the special tools, secure the engine to the lift table.
    Fig 3: Securing Engine To Lift Table Using Special Tool (014-0001, 014-00765)
    G03897890Courtesy of FORD MOTOR CO.
  6. Raise the engine and transaxle into the vehicle.
  7. Install the bolt in the LH transaxle mount.
    • Tighten to 103 N.m (76 lb-ft).
      Fig 4: Locating Transaxle Mount Bolt
      G03897894Courtesy of FORD MOTOR CO.
  8. Install the bolt in the rear transaxle mount.
    • Tighten to 115 N.m (85 lb-ft).
      Fig 5: Locating Rear Transaxle Mount Bolt
      G04618347Courtesy of FORD MOTOR CO.
  9. Install the engine mount bracket.
    • Tighten to 115 N.m (85 lb-ft).
      Fig 6: Locating Engine Mount Bracket
      G04618348Courtesy of FORD MOTOR CO.
  10. Install the engine mount bracket bolt.
    • Tighten to 115 N.m (85 lb-ft).
      Fig 7: Locating Engine Mount Bracket Bolt
      G04618349Courtesy of FORD MOTOR CO.
  11. Install the 2 transaxle-to-engine bolts.
    • Tighten to 48 N.m (35 lb-ft).
      Fig 8: Locating Transaxle-To-Engine Bolts (1 Of 2)
      G04618350Courtesy of FORD MOTOR CO.
  12. Install the 2 transaxle-to-engine bolts.
    • Tighten to 48 N.m (35 lb-ft).
      Fig 9: Locating Transaxle-To-Engine Bolts (2 Of 2)
      G04618351Courtesy of FORD MOTOR CO.
  13. Install the engine support crossmember and new nut.
    • Tighten to 175 N.m (129 lb-ft).
      Fig 10: Identifying Cross Brace And Rear Nut
      G03897887Courtesy of FORD MOTOR CO.
  14. Install the 2 bolts for the engine support crossmember and the front roll restrictor bolt.
    • Tighten the engine support crossmember bolts to 90 N.m (66 lb-ft).
    • Tighten the front roll restrictor bolt to 115 N.m (85 lb-ft).
      Fig 11: Identifying Front Roll Restrictor Bolt & Bolts For Engine Support Crossmember
      G04619986Courtesy of FORD MOTOR CO.
    15. NOTE: The bolt under the power steering pressure tube will remain with the power steering pump.
  15. Position the power steering pump and install the bolts.
    • Tighten to 25 N.m (18 lb-ft).
      Fig 12: Identifying Power Steering Pump Bolts
      G03897742Courtesy of FORD MOTOR CO.
  16. Connect the power steering pressure (PSP) sensor electrical connector.
    Fig 13: Locating Power Steering Pressure (PSP) Sensor Electrical Connector
    G04618355Courtesy of FORD MOTOR CO.
  17. Install the A/C compressor and connect the A/C compressor electrical connector.
    • Tighten the bolts to 25 N.m (18 lb-ft).
      Fig 14: Locating A/C Compressor & Bolts
      G04618356Courtesy of FORD MOTOR CO.
  18. Connect the lower radiator hose to the radiator.
    Fig 15: Locating Lower Radiator Hose
    G03897882Courtesy of FORD MOTOR CO.
  19. Install the 2 power steering pump bolts.
    • Tighten to 25 N.m (18 lb-ft).
      Fig 16: Locating Power Steering Pump Bolts
      G03897741Courtesy of FORD MOTOR CO.
  20. Install the ground wire and bolt.
    • Tighten to 10 N.m (89 lb-in).
      Fig 17: Locating Ground Wire & Bolt
      G03897880Courtesy of FORD MOTOR CO.
  21. Connect the powertrain control module (PCM) electrical connectors. Position the harness and install the nut.
    • Tighten to 8 N.m (71 lb-in).
      Fig 18: Locating Powertrain Control Module (PCM) Electrical Connectors
      G03897879Courtesy of FORD MOTOR CO.
  22. Attach the electrical connector retainers.
    Fig 19: Locating Electrical Connector Retainers
    G04618361Courtesy of FORD MOTOR CO.
  23. Connect the fuel supply tube.
    Fig 20: Locating Fuel Supply Tube
    G04618362Courtesy of FORD MOTOR CO.
  24. Connect the vacuum reservoir tube.
    Fig 21: Locating Vacuum Reservoir Tube
    G04618363Courtesy of FORD MOTOR CO.
  25. Connect the fuel vapor return tube and retainer.
    Fig 22: Locating Fuel Vapor Return Tube & Retainer
    G04618364Courtesy of FORD MOTOR CO.
  26. Connect the vacuum supply tube.
    Fig 23: Locating Vacuum Supply Tube
    G04618365Courtesy of FORD MOTOR CO.
  27. Install the power steering tube, bracket and nut.
    • Tighten to 6 N.m (53 lb-in).
      Fig 24: Locating Power Steering Tube, Bracket & Nut
      G04618366Courtesy of FORD MOTOR CO.
  28. Position the accelerator control cable and bracket and install the nut.
    • Tighten to 9 N.m (80 lb-in) (vehicles built through 10/2005).
    • Tighten to 5 N.m (44 lb-in) (vehicles built after 10/2005).
      Fig 25: Locating Accelerator Control Cable & Bracket
      G04618367Courtesy of FORD MOTOR CO.
  29. Install the accelerator control cable and bracket and nut.
    • Tighten to 9 N.m (80 lb-in) (vehicles built through 10/2005).
    • Tighten to 5 N.m (44 lb-in) (vehicles built after 10/2005).
      Fig 26: Locating Accelerator Control Cable, Bracket & Nut
      G04618368Courtesy of FORD MOTOR CO.
  30. Install the accelerator cable and speed control cable (if equipped).
    1. Connect the accelerator and speed control cable (if equipped) to the throttle body.
    2. Install the accelerator cable bracket and bolts.
      • Tighten to 10 N.m (89 lb-in).
        Fig 27: Identifying Accelerator Cable Bracket & Bolts
        G04618369Courtesy of FORD MOTOR CO.
  31. Install the accelerator cable snow shield and retainers.
    • Tighten to 10 N.m (89 lb-in).
      Fig 28: Locating Accelerator Cable Snow Shield & Retainers
      G04618370Courtesy of FORD MOTOR CO.
  32. Connect the heater hoses to the heater core.
    Fig 29: Locating Heater Hoses
    G03897868Courtesy of FORD MOTOR CO.
  33. Attach the heater hose support strap to the stud.
    Fig 30: Locating Heater Hose Support Strap
    G04618372Courtesy of FORD MOTOR CO.
  34. Position the coolant vent hose and install the coolant vent hose brackets and nuts.
    • Tighten to 10 N.m (89 lb-in).
      Fig 31: Locating Coolant Vent Hose
      G04618373Courtesy of FORD MOTOR CO.
  35. Connect the upper radiator and coolant vent hoses.
    Fig 32: Locating Upper Radiator & Coolant Vent Hoses
    G04618374Courtesy of FORD MOTOR CO.
  36. If equipped, route the block heater wiring harness and attach all retainers. Connect the block heater electrical connector.
    Fig 33: Locating Block Heater Wiring Harness
    G04618375Courtesy of FORD MOTOR CO.
  37. Attach the transaxle control harness to the retaining clip.
    Fig 34: Locating Transaxle Control Harness
    G04618376Courtesy of FORD MOTOR CO.
  38. Install the output shaft speed (OSS) sensor and bolt.
    • Tighten to 13 N.m (10 lb-ft).
      Fig 35: Locating OSS Sensor Bolt
      G03897862Courtesy of FORD MOTOR CO.
  39. Install the fluid cooler tube.
    1. Connect the OSS sensor.
    2. Connect the turbine shaft speed (TSS) sensor (white connector).
    3. Position the bracket and install the bolt.
      • Tighten 13 N.m (10 lb-ft).
    4. Position the fluid cooler tube.
      • Tighten to 23 N.m (17 lb-ft).
        Fig 36: Locating Fluid Cooler Tube
        G04618378Courtesy of FORD MOTOR CO.
  40. Connect the rear transmission fluid cooler tube.
    Fig 37: Locating Rear Transmission Fluid Cooler Tube
    G04618379Courtesy of FORD MOTOR CO.
  41. Connect the front transmission fluid cooler tube.
    • Tighten to 23 N.m (17 lb-ft).
      Fig 38: Locating Transmission Fluid Cooler Tube
      G03897859Courtesy of FORD MOTOR CO.
  42. Attach the transaxle control harness to the brackets.
    Fig 39: Locating Transaxle Control Harness
    G04618381Courtesy of FORD MOTOR CO.
  43. Connect the transmission range (TR) sensor electrical connector.
    Fig 40: Locating Transmission Range (TR) Sensor Electrical Connector
    G03897857Courtesy of FORD MOTOR CO.
  44. Install the transaxle control cable, bracket and bolts.
    • Tighten to 19 N.m (14 lb-ft).
    • Attach the wiring harness pin-type retainers.
      Fig 41: Locating Transaxle Control Cable, Bracket & Bolts
      G04618383Courtesy of FORD MOTOR CO.
  45. Connect the shift cable to the transaxle manual lever.
    Fig 42: Locating Shift Cable End At Manual Lever
    G03897855Courtesy of FORD MOTOR CO.
  46. Connect the transaxle electrical connector.
    Fig 43: Locating Transaxle Electrical Connector
    G04618385Courtesy of FORD MOTOR CO.
  47. Attach the wiring harness retainers to the battery tray bracket.
    Fig 44: Locating Wiring Harness Retainers
    G04618386Courtesy of FORD MOTOR CO.
  48. Connect the 42-pin electrical connector and tighten the bolt. Install the ground strap and bolt.
    • Tighten to 10 N.m (89 lb-in).
      Fig 45: Locating Ground Strap & Electrical Connector
      G03897852Courtesy of FORD MOTOR CO.
  49. Connect the electrical connector to the power distribution box.
    Fig 46: Locating Electrical Connector
    G04618388Courtesy of FORD MOTOR CO.
  50. Connect the cables and install the nuts.
    • Tighten to 12 N.m (9 lb-ft).
      Fig 47: Locating Cables & Nuts
      G03897850Courtesy of FORD MOTOR CO.
  51. Install the power distribution box cover.
    Fig 48: Locating Power Distribution Box Cover
    G03897849Courtesy of FORD MOTOR CO.
  52. If equipped, install the ground eyelet and bolt.
    • Tighten to 10 N.m (89 lb-in).
      Fig 49: Locating Ground Eyelet & Bolt
      G04618391Courtesy of FORD MOTOR CO.

    53. 4x2 vehicles 

  53. Install the front drive intermediate halfshaft. For additional information, refer to INSTALLATION .
  54. Install the lateral support crossmember and bolts.
    • Tighten to 115 N.m (85 lb-ft).
      Fig 50: Identifying Lateral Support Crossmember And Bolts
      G03897847Courtesy of FORD MOTOR CO.

    55. 4x4 vehicles 

  55. Install the transfer case. For additional information, refer to TRANSFER CASE-POWER TRANSFER UNIT (PTU) .

    56. All vehicles 

  56. Install the LH front drive halfshaft. For additional information, refer to INSTALLATION .
  57. Install the generator shield and the nut and the pin-type retainer and attach the wire retainers.
    • Tighten to 20 N.m (15 lb-ft).
      Fig 51: Locating Generator Shield & Nut
      G04618393Courtesy of FORD MOTOR CO.
  58. Install the lower air duct and install the bolt.
    • Tighten to 4 N.m (35 lb-in).
      Fig 52: Locating Lower Air Duct & Bolt
      G04618394Courtesy of FORD MOTOR CO.
  59. Install the accessory drive belt tensioner. For additional information, refer to REMOVAL AND INSTALLATION .
  60. Connect the heated oxygen sensor (HO2S) and the catalyst monitor sensor electrical connectors.
    Fig 53: Locating Heated Oxygen Sensor (HO2S) & Catalyst Monitor Sensor Electrical Connectors
    G04618395Courtesy of FORD MOTOR CO.
  61. Install the exhaust flexible pipe. For additional information, refer to REMOVAL AND INSTALLATION .
  62. Install the starter. For additional information, refer to STARTING SYSTEM .
  63. Install the battery tray and battery. For additional information, refer to REMOVAL AND INSTALLATION - BATTERY TRAY and REMOVAL AND INSTALLATION - BATTERY .
  64. Install the engine air cleaner and air cleaner outlet pipe. For additional information, refer to REMOVAL AND INSTALLATION - AIR CLEANER and REMOVAL AND INSTALLATION - AIR CLEANER OUTLET PIPE .
  65. Fill the engine with clean engine oil.
  66. Fill and bleed the cooling system. For additional information, refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
RENDER: 1.0x

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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.