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HOMESERVICE MANUALSFORD2005TAURUS SEL, 4D SEDANREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 367 (MANUAL TRANSMISSION)INSTALLATIONTRANSAXLE
2005 Ford Taurus SEL, 4D Sedan

Section 367 (Manual Transmission): Installation: Transaxle

2005 Ford Taurus SEL, 4D SedanSECTION Transaxle
WARNING: This page is about a different car, the 2006 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL

G04621086Courtesy of FORD MOTOR CO.
 3-Bar Engine Support Kit
303-F072 or equivalent
MATERIAL SPECIFICATION

Item Specification
Premium Long-Life Grease
XG-1-C or XG-1-K (US); CXG-1-C (Canada)		 ESA-M1C75-B
High Performance DOT 3 Motor Vehicle Brake Fluid
PM-1-C (US); CPM-1-C (Canada)		 WSS-M6C62-A
  1. Do not lubricate the splines on the input shaft.
    2. WARNING: Secure the transaxle to the transmission jack with a safety chain. Failure to follow these instructions may result in personal injury.
  2. Raise and position the transaxle.
  3. Install the 5 short transaxle-to-engine bolts.
    • Tighten to 47 Nm (35 lb-ft).
  4. Install the long transaxle-to-engine bolt.
    • Tighten to 47 Nm (35 lb-ft).
  5. Install the exhaust outlet pipe. For additional information, refer to EXHAUST SYSTEM .
  6. Install the transaxle front support insulator bracket.
    1. Install the transaxle front support insulator bracket.
    2. Install the 3 bolts.
      • Tighten to 48 Nm (35 lb-ft).
    3. Install the transaxle front support insulator.
    4. Install the through-bolt.
      • Tighten to 115 Nm (85 lb-ft).
        Fig 1: Identifying Transaxle Front Support Insulator And Bolts
        G04621087Courtesy of FORD MOTOR CO.
    7. CAUTION: Make sure to use the seal protector when installing the RH intermediate shaft and the LH halfshaft. Failure to use the seal protector may result in transmission oil leaks.
  7. Install the RH intermediate axleshaft and the LH halfshaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
  8. If equipped, install the transfer case. For additional information, refer to TRANSFER CASE-POWER TRANSFER UNIT (PTU) .
  9. Install the starter motor assembly. For additional information, refer to STARTING SYSTEM .
  10. Install the LH side splash shield.
    1. Position the LH splash shield.
    2. Install the 2 screws.
      Fig 2: Identifying LH Splash Shield And Screws
      G04621088Courtesy of FORD MOTOR CO.
  11. Install the 3 LH splash shield screws.
    Fig 3: Locating LH Splash Shield Screws
    G04621089Courtesy of FORD MOTOR CO.
  12. Install the front-to-aft crossmember.
    1. Position the crossmember.
    2. Install the 2 bolts and nut.
      • Tighten the bolts to 90 Nm (66 lb-ft).
      • Tighten the new nut to 175 Nm (129 lb-ft).
    3. Install the splash shield screw.
    4. Install the 2 transaxle front support insulator bolts.
      • Tighten to 90 Nm (66 lb-ft).
        Fig 4: Identifying Transaxle Front Support Insulator Bolts And Nuts
        G04621090Courtesy of FORD MOTOR CO.
  13. Install the crossmember.
    1. Position the crossmember.
    2. Install the bolts.
      • Tighten to 115 Nm (85 lb-ft).
        Fig 5: Identifying Crossmember And Bolts
        G04621091Courtesy of FORD MOTOR CO.
  14. Install the 3 upper transaxle-to-engine bolts. Tighten the bolts to 47 Nm (35 lb-ft).
    Fig 6: Locating Upper Transaxle-To-Engine Bolts
    G04621092Courtesy of FORD MOTOR CO.
  15. Install the transaxle rear support insulator.
    1. Position the transaxle rear support insulator.
    2. Install the through-bolt.
      • Tighten to 115 Nm (85 lb-ft).
    3. Install the nuts.
      • Tighten to 80 Nm (59 lb-ft).
    4. Install the bolt.
      • Tighten to 80 Nm (59 lb-ft).
        Fig 7: Identifying Transaxle Rear Support Insulator Bolts
        G04621093Courtesy of FORD MOTOR CO.
  16. 16 Install the LH transaxle support insulator bracket.
    1. Position the LH transaxle support insulator bracket.
    2. Install the through-bolt.
      • Tighten to 103 Nm (76 lb-ft).
    3. Install the 3 nuts.
      • Tighten to 40 Nm (30 lb-ft).
        Fig 8: Identifying LH Transaxle Support Insulator Bracket And Bolt
        G04621094Courtesy of FORD MOTOR CO.
  17. Install the shift cable bracket.
    1. Position the shift cable bracket.
    2. Install the 3 bolts.
      • Tighten to 22 Nm (16 lb-ft).
        Fig 9: Identifying Shift Cable Bracket And Bolt
        G04621095Courtesy of FORD MOTOR CO.
  18. Connect the clutch hydraulic line.
    1. Position the clutch hydraulic line.
    2. Connect the clutch hydraulic line from the clutch slave cylinder.
    3. Install the clutch hydraulic line bracket-to-transaxle bolt.
      • Tighten to 2.5 Nm (22 lb-in).
        Fig 10: Identifying Clutch Hydraulic Line From Clutch Slave Cylinder
        G04621096Courtesy of FORD MOTOR CO.
  19. Connect the shift cables.
    Fig 11: Locating Shift Cables
    G04621097Courtesy of FORD MOTOR CO.
  20. Connect the reverse switch and vehicle speed sensor (VSS) connectors.
    Fig 12: Locating Reverse Switch And Vehicle Speed Sensor (VSS) Connectors
    G04621098Courtesy of FORD MOTOR CO.
  21. Install the wiring harness bracket nuts.
    • Tighten to 12 Nm (9 lb-ft).
      Fig 13: Locating Wiring Harness Bracket Nuts
      G04621099Courtesy of FORD MOTOR CO.
  22. Install the air cleaner outlet tube.
    1. Install the air cleaner outlet tube.
    2. Tighten the clamp.
    3. Connect the emission management tube and hose.
      Fig 14: Identifying Air Cleaner Outlet Tube And Clamp
      G04621100Courtesy of FORD MOTOR CO.
  23. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  24. Install the air cleaner assembly. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING - 2.3L .
  25. Fill the transaxle fluid. For additional information, refer to TRANSAXLE DRAINING AND FILLING .
    26. 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 personal injury.
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.