How do you change a transmission on a 1995-98 Ford Windstar?

Answer 1

I have 2 1996 LX-3.8LI just rebuilt AX4S trans,2 different ways I like the this one the best,,remove engine cover(5 bolts 8mm one grd and 4 hood hinge)remove antenna,windshield wipers,remove black windshield grill(7 screws)remove windshield wiper motor support(11 8mm bolts) and unplug the wind shield wiper motor ele. plug,remove lower radiador hose,upper radiador hose,also remove heater hose above radiador hose on right side(looking into engine compartment all instrustions will be looking into engine compartment)there is a heater hose on the left side of engine toward firewall,remove the main wiring harness on the right side(10mm)there are 2more wire harness plugs toward firewall below the main harness to remove,remove the computer harness plug(10mm)remove the following plugs A/C,both battery cables(8mm)2 nuts(15mm) off the back of the fuse relay box at the rear of box(this is next to the battery) speed sensor on side of trans(you have to remove both front tires)1 grd wire on the A/C drier mounting bracket,1 grd on the bottom of frame located above the left axle(8mm)unscrew speed O cable on the right side in the middle of the cable,the is a wire plug(VSS) located at the end od the speed O cable itshard to get to so I cut them and install a plug when engine is out,now remove the the air intakes on the firewall the bg one has 2 10mm nuts one on top and one on the bottom there are 2 vacuum lines attached to it remember where they go,pull forward on the little air intake it will pop off,remove vacuum plug above A/C drier,battery cables from starter O2 sensor plug in front of the starter(green)remove the rear O2 sensor plug from the rear exhaust(green plug)remove both exhaust flanges(front&back 15mm)remove engine mount nut lower rihgt side(18mm) remove front mount bolt and nut(18mm)remove lower sturt ball joint bolts and nuts(18mm)and take the ball joints out of control arms,pop both inner vc axles out of trans,remove 4 13mm bolts from rear of trans, remove stsrter abd cover to remove 4 15mm nuts from torque converter,the hard part is to remove 4 10mm bolts from A/C compressor if you don't want to redo the gas R134remove the 18mm nut from front mount on the top of mount its in between the eng. and a/c compressor,remove the crankshaft pully 4 13mm bolts,chain engine to the middle exhaust manifolds on each side,remove battery holder and cruise control and wire plug,remove the 2 hoses from Power Steering pump,set those steel lines to the front of the eng.remove the 2 trans lines from the trans. This will allow you remove the engine and transmission at the same time,remember AX4S is not one of the best so if your doing engine work this is the time to freshen up the trans(each to there own,but this happened to me new engine the trans went out a week later!!)your ready to pull the engine and trans,BUT if you want just the engine out leave the struts and the axles and the 2 plugs and speed O cable in and take take starter bolts and 5 bolts 15mm out of trans one trans bolt hard to get to in between the eng. and trans lower side also leave the 4 13mm bolts in at the rear of trans but its easier to take both at th same time! Also leave the car as level as possible theres 2 support pads right in front of drivers and passenger front doors,It takes about 3 hours to remove eng. and trans,This all sounds crazy but not bad and I do it by myself.I don't know if you have vacum pump and gauges(79.00 for vac pump and 45.00 for gauges) to do A/C work.I hope this is complete I might have missed a plug,Take your time and keep your cool.The engine comes out with the wire harness intacked,Take air cleaner and plug and hose off the gas and cruise cable have 2 8mm bolts holding it to the thottle body removing everything from the battery compartment helps you to see and remove plugs and parts.There are 3 big vacuum lines brake booster and 2 on the intake by the thottle body and the pcv hose,I forgot but look before you pull,That should cover it,if you find something I've missed please add it,I did jump around here but I am sure you'll do all work on bottom last! do water drain last less mess.Thank you fr letting me help,also I can help with AX4S(AXOD) trans,do not try and take engine out the bottom if you don't have a lift,that would be very HARD and alot of help needed,and if your thinking of building th eng. the crank and rods will have to be bought new 3.8 eng rods are junk there called broken rods which descibes how there made and they can not be reconditioned and the crank is the same way,I had 160,000 on eng. and found it was cheaper to buy a long block (heads installed) 1250.00 from a good mfg.I am Airframe and Powerplant mec. for aircraft and have 8 ASE cert. and worked in both industries for 40 years,

REMOVAL

Transaxle

Special Tool(s)

Fig. 274: Identifying Special Tools (1 Of 3)

Courtesy of Ford MOTOR CO.

Fig. 275: Identifying Special Tools (2 Of 3)

Courtesy of FORD MOTOR CO.

Fig. 276: Identifying Special Tools (3 Of 3)

Courtesy of FORD MOTOR CO.

Remove the air cleaner assembly. .

NOTE:When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy.

Remove the battery and tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .

Disconnect the electrical connectors.

Disconnect the digital transmission range (TR) sensor electrical connector.

Disconnect the transaxle electrical connector.

Disconnect the wire harness from the bracket.

Disconnect the shift cable.

Remove the cable from the bracket.

Disconnect the wire harness from the bracket.

Remove the manual control lever.

Remove the hood.

Remove the wiper arm and pivot assembly. For additional information, refer to WIPERS AND WASHERS .

Remove the front upper radiator shield.

Install the special tool.

Install the special tool.

Install the special tools.

Install the special tool.

Remove the bolt and the upper fluid filler tube.

Remove the clips.

Depress the tabs on the plastic insert retainer and remove the cooler line from fitting.

Remove the transaxle retaining bolts.

Remove the rear transaxle mount nut.

Raise and support the vehicle. For additional information, refer to JACKING & LIFTING .

Remove the front wheel and tires. For additional information, refer to WHEELS & TIRES .

Drain the Transmission Fluid by lowering the transaxle pan.

NOTE:The transaxle fluid pan does not need to be torqued in this step.

Install the transaxle pan.

Remove the three way catalytic converter assembly. For additional information, refer to EXHAUST SYSTEM .

Disconnect the LH knuckle assembly.

Disconnect the LH tie rod assembly.

Disconnect the LH sway bar assembly.

Remove the LH pinch bolt.

Disconnect the RH knuckle assembly.

Disconnect the RH tie rod assembly.

Disconnect the RH sway bar assembly.

Remove the RH pinch bolt.

Remove the nuts for the power steering rack.

Disconnect the retainer for the power steering line.

Disconnect the retainer for the power steering line.

Remove the front engine mount.

Remove the rear engine mount.

Position a suitable lift under the vehicle and raise it to the subframe.

Remove the left front subframe bolt.

Remove the right front subframe bolt.

Remove the left rear subframe bolt.

NOTE:Disconnect the heat shield from the subframe prior to lowering it from the vehicle.

Remove the right rear subframe bolt and lower the subframe assembly.

Remove two bolts from the LH sway bar assembly.

Remove two bolts from the RH sway bar assembly.

Remove the sway bar assembly.

Install the special tool.

The use of mechanic's wire will aid in holding the power steering rack up in the vehicle.

Remove the ground strap and harness bracket.

NOTE:The use of mechanic's wire will aid in positioning the starter out of the way.

Remove the starter and position it out of the way.

Loosen the inspection cover bolt, and remove the pushpin.

Remove both parts of the inspection cover.

Remove and discard the four nuts.

NOTE:The use of mechanic's wire will aid in positioning the halfshafts out of the way.

Using the special tools, remove the LH halfshaft from the transaxle and position out of the way.

NOTE:The use of mechanic's wire will aid in positioning the halfshafts out of the way.

Using the special tools, remove the RH halfshaft from the transaxle and position out of the way.

Disconnect the output shaft speed (OSS) sensor connector.

Disconnect the turbine shaft speed (TSS) sensor connector.

Position the high lift transmission jack under the transaxle.

Remove the rear lower retaining bolt.

Remove the front lower retaining bolt.

Remove the oil pan to transaxle retaining bolt.

Remove the oil pan to transaxle retaining bolt.

Remove the transaxle retaining bolts.

Lower the transaxle assembly from the engine compartment.

Remove the bracket.

Remove the rear support bracket.

Carry out the transmission fluid cooler backflushing/cleaning. For additional information, refer to TRANSMISSION FLUID COOLER - BACKFLUSHING AND CLEANING .