2006 Ford Freestar BaseFACTORY OEM SERVICE PROCEDURE

Automatic Transmission: Installation: Transaxle

SPECIAL TOOL(S)

G04661690Courtesy of FORD MOTOR CO.
 Lifting Bracket Set, Engine
303-D095 (D94L-6001-A) or equivalent
G04661691Courtesy of FORD MOTOR CO.
 Support Bar, Engine
303-290-A
G04661692Courtesy of FORD MOTOR CO.
 Adapter for 303-290A (Support Leg)
303-290A-03A
G04661693Courtesy of FORD MOTOR CO.
 Adapter for 303-290A (Spreader Bar)
303-290A-10
G04661694Courtesy of FORD MOTOR CO.
 Adapter for 303-290A (Support Bracket)
303-290A-11
G04661695Courtesy of FORD MOTOR CO.
 Lifting Brackets, Engine
303-D119
G04661696Courtesy of FORD MOTOR CO.
 Adapter for 303-290A (Strut)
303-290A-09
MATERIALS

Item Specification
MERCON® V Automatic Transmission Fluid XT-5-QM (or XT-5-QMC) (US); CXT-5-LM12 (Canada) MERCON® V
Multi-Purpose Grease XG-4 and/or XL-5 ESB-M1C93-B
  1. Secure the transaxle on a high lift transmission jack. Apply multi-purpose grease to the torque converter pilot hub.
    Fig 1: Identifying Torque Converter Pilot Hub
    G04661697Courtesy of FORD MOTOR CO.
  2. Install the shift cable bracket and bolts.
    • Tighten to 35 Nm (26 lb-ft).
      Fig 2: Locating Shift Cable Bracket And Bolts
      G04661698Courtesy of FORD MOTOR CO.
  3. If not previously installed, install the heat shield.
    Fig 3: Locating Heat Shield
    G04661699Courtesy of FORD MOTOR CO.
  4. If not previously installed, install the rear engine support bracket.
    • Tighten to 62 Nm (46 lb-ft).
      Fig 4: Locating Rear Engine Support Bracket Bolts
      G04661700Courtesy of FORD MOTOR CO.
  5. Verify the position of the special tools.
    Fig 5: Identifying Position Of Special Tools (303-290A), (303-290A-03A), (303-290A-09), (303-290A-10), And (303-D095)
    G04661701Courtesy 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 6: Identifying Transaxle Retaining Bolts
      G04661702Courtesy of FORD MOTOR CO.
  8. Install the oil pan-to-transaxle case bolt.
    • Tighten to 47 Nm (35 lb-ft).
      Fig 7: Locating Oil Pan-To-Transaxle Case Bolt
      G04661703Courtesy of FORD MOTOR CO.
  9. Install the oil pan-to-transaxle case bolt.
    • Tighten to 47 Nm (35 lb-ft).
      Fig 8: Locating Oil Pan-To-Transaxle Case Bolt
      G04661704Courtesy of FORD MOTOR CO.
  10. Install the front lower retaining bolt.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 9: Identifying Front Lower Retaining Bolt
      G04661705Courtesy of FORD MOTOR CO.
  11. Install the rear lower retaining bolt.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 10: Identifying Rear Lower Retaining Bolt
      G04661706Courtesy of FORD MOTOR CO.
  12. Remove the high-lift transmission jack.
  13. Connect the turbine shaft speed (TSS) sensor electrical connector.
    Fig 11: Identifying High-Lift Transmission Jack
    G04661707Courtesy of FORD MOTOR CO.
  14. Connect the output shaft speed (OSS) sensor electrical connector.
    Fig 12: Identifying Output Shaft Speed (OSS) Sensor Electrical Connector
    G04661708Courtesy of FORD MOTOR CO.
  15. Install the RH halfshaft.
    Fig 13: Identifying RH Halfshaft
    G04661709Courtesy of FORD MOTOR CO.
  16. Install the LH halfshaft.
    Fig 14: Identifying LH Halfshaft
    G04661710Courtesy 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.
  17. Install 4 new torque converter nuts.
    • Tighten to 47 Nm (35 lb-ft).
      Fig 15: Identifying Torque Converter Nuts
      G04661711Courtesy of FORD MOTOR CO.
  18. Install the 2-piece transaxle housing cover.
    Fig 16: Identifying Piece Transaxle Housing Cover
    G04661712Courtesy of FORD MOTOR CO.
  19. Install the pushpin for the inspection cover.
    Fig 17: Identifying Pushpin For Inspection Cover
    G04661713Courtesy of FORD MOTOR CO.
  20. Tighten the transaxle inspection cover bolt and pushpin.
    • Tighten to 10 Nm (89 lb-in).
      Fig 18: Identifying Transaxle Inspection Cover Bolt
      G04661714Courtesy of FORD MOTOR CO.
  21. Install the starter motor.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 19: Locating Starter Motor Bolts
      G04661715Courtesy of FORD MOTOR CO.
  22. Install the ground strap.
    • Tighten to 20 Nm (15 lb-ft).
      Fig 20: Locating Ground Strap Bolt
      G04661716Courtesy of FORD MOTOR CO.
  23. Raise the subframe assembly into position. Connect the heat shield to the subframe.
  24. Using a 19 mm (0.76 in) dowel, check the front subframe alignment.
    • The dowel should slide directly through the front subframe and body without tilting.
      Fig 21: Checking Front Subframe Alignment
      G04661717Courtesy of FORD MOTOR CO.
  25. Install the sway bar assembly.
    Fig 22: Locating Sway Bar Assembly
    G04661718Courtesy of FORD MOTOR CO.
  26. Install 2 bolts for the RH sway bar retainer.
    • Tighten to 62 Nm (46 lb-ft).
      Fig 23: Locating RH Sway Bar Retainer Bolts
      G04661719Courtesy of FORD MOTOR CO.
  27. Install 2 bolts for the LH sway bar retainer.
    • Tighten to 62 Nm (46 lb-ft).
      Fig 24: Locating LH Sway Bar Retainer Bolts
      G04661720Courtesy of FORD MOTOR CO.
  28. Install the right rear subframe bolt.
    • Tighten to 175 Nm (129 lb-ft).
      Fig 25: Locating Right Rear Subframe Bolt
      G04661721Courtesy of FORD MOTOR CO.
  29. Install the left rear subframe bolt.
    • Tighten to 175 Nm (129 lb-ft).
      Fig 26: Identifying Left Rear Subframe Bolt
      G04661722Courtesy of FORD MOTOR CO.
  30. Install the right front subframe bolt.
    • Tighten to 175 Nm (129 lb-ft).
      Fig 27: Locating Right Front Subframe Bolt
      G04661723Courtesy of FORD MOTOR CO.
  31. Install the left front subframe bolt.
    • Tighten to 175 Nm (129 lb-ft).
      Fig 28: Locating Left Front Subframe Bolt
      G04661724Courtesy of FORD MOTOR CO.
  32. Install the rear engine mount.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 29: Locating Rear Engine Mount Bolts
      G04661725Courtesy of FORD MOTOR CO.
  33. Install the front engine mount.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 30: Identifying Front Engine Mount Bolt
      G04661726Courtesy of FORD MOTOR CO.
  34. Install the retainer for the power steering line.
    • Tighten to 6 Nm (53 lb-in).
      Fig 31: Locating Retainer For Power Steering Line Bolt
      G04661727Courtesy of FORD MOTOR CO.
  35. Install the retainer for the power steering hose.
    Fig 32: Locating Retainer For Power Steering Hose
    G04661728Courtesy of FORD MOTOR CO.
  36. Install the nuts for the power steering rack.
    • Tighten to 175 Nm (129 lb-ft).
      Fig 33: Locating Power Steering Rack Nut
      G04661729Courtesy of FORD MOTOR CO.
  37. Connect the RH knuckle assembly.
    1. Connect the RH tie-rod assembly.
      • Tighten to 80 Nm (59 lb-ft).
    2. Connect the RH sway bar assembly.
      • Tighten to 90 Nm (66 lb-ft) (vehicles built through 12/2005).
      • Tighten to 103 Nm (76 lb-ft) (vehicles built after 12/2005).
    3. Install the RH pinch bolt.
      • Tighten to 90 Nm (66 lb-ft).
        Fig 34: Connecting RH Knuckle Assembly
        G04661730Courtesy of FORD MOTOR CO.
  38. Connect the LH knuckle assembly.
    1. Connect the LH tie-rod assembly.
      • Tighten to 80 Nm (59 lb-ft).
    2. Connect the LH sway bar assembly.
      • Tighten to 90 Nm (66 lb-ft) (vehicles built through 12/2005).
      • Tighten to 103 Nm (76 lb-ft) (vehicles built after 12/2005).
    3. Install the LH pinch bolt.
      • Tighten to 90 Nm (66 lb-ft).
        Fig 35: Connecting LH Tie-Rod Assembly
        G04661731Courtesy of FORD MOTOR CO.
  39. Install the catalytic converter assembly. For additional information, refer to EXHAUST SYSTEM .
  40. Install the rear transaxle mount nut.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 36: Locating Rear Transaxle Mount Nut
      G04661732Courtesy of FORD MOTOR CO.
  41. Install the anti-roll bracket and the 4 bolts.
    1. Tighten to 62 Nm (46 lb-ft).
    2. Tighten to 30 Nm (22 lb-ft).
    3. Tighten to 90 Nm (66 lb-ft).
      Fig 37: Identifying Anti-Roll Bracket And Bolts
      G04661733Courtesy of FORD MOTOR CO.
  42. Install the 2 transaxle retaining bolts.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 38: Locating Transaxle Retaining Bolts
      G04661734Courtesy of FORD MOTOR CO.
  43. Connect the transaxle fluid cooler tubes.
    Fig 39: Locating Transaxle Fluid Cooler Tubes
    G04661735Courtesy of FORD MOTOR CO.
  44. Install the retaining clips.
    Fig 40: Locating Retaining Clips
    G04661736Courtesy of FORD MOTOR CO.
  45. Install the upper transaxle fluid filler tube and bolt.
    • Tighten to 14 Nm (10 lb-ft).
      Fig 41: Locating Upper Transaxle Fluid Filler Tube And Bolt
      G04661737Courtesy of FORD MOTOR CO.
  46. Install the oil filler cap.
    Fig 42: Locating Oil Filler Cap
    G04661738Courtesy of FORD MOTOR CO.
  47. Install the hood latch.
    • Tighten to 12 Nm (9 lb-ft).
      Fig 43: Locating Hood Latch Bolts
      G04661739Courtesy of FORD MOTOR CO.
  48. Install the front upper radiator shield.
    Fig 44: Locating Front Upper Radiator Shield
    G04661740Courtesy of FORD MOTOR CO.
  49. Install the air intake tube.
    Fig 45: Locating Air Intake Tube
    G04661741Courtesy of FORD MOTOR CO.
  50. Install the passenger compartment air intake box.
    Fig 46: Locating Passenger Compartment Air Intake Box
    G04661742Courtesy of FORD MOTOR CO.
  51. Install the wiper arm and pivot assembly. For additional information, refer to WIPERS AND WASHERS .
  52. Install the hood.
  53. Verify that the digital transmission range (TR) sensor is correctly adjusted. For additional information, refer to DIGITAL TRANSMISSION RANGE (TR) SENSOR  in this article.
  54. Install the manual control lever and nut.
    • Tighten to 13 Nm (10 lb-ft).
      Fig 47: Locating Manual Control Lever And Nut
      G04661743Courtesy of FORD MOTOR CO.
  55. Reconnect the harness retainer.
    Fig 48: Locating Harness Retainer
    G04661744Courtesy of FORD MOTOR CO.
  56. Install the shift cable in the bracket.
    Fig 49: Locating Shift Cable In Bracket
    G04661745Courtesy of FORD MOTOR CO.
  57. Connect the shift cable to the manual control lever.
    Fig 50: Locating Shift Cable To Manual Control Lever
    G04661746Courtesy of FORD MOTOR CO.
  58. Connect the electrical connectors.
    1. Connect the TR sensor electrical connector.
    2. Connect the transaxle electrical connector.
    3. Connect the speed control electrical connector.
      Fig 51: Locating Electrical Connectors
      G04661747Courtesy of FORD MOTOR CO.
  59. Install the air cleaner assembly. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING .
    Fig 52: Identifying Air Cleaner Assembly
    G04661748Courtesy of FORD MOTOR CO.
  60. Install the air cleaner tube and tighten the hose clamps.
    Fig 53: Locating Air Cleaner Tube
    G04661749Courtesy of FORD MOTOR CO.
    61. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive shift strategy.
  61. Install the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  62. Fill the transaxle using clean automatic transmission fluid.
  63. Start the engine. Move the transaxle range selector lever through all positions. Check the fluid level. For additional information, refer PRELIMINARY INSPECTION  in this article.
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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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