2003 Mercury Sable

Tiny
JKABN
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  • 2003 MERCURY SABLE
Transmission problem
2003 Mercury Sable 6 cyl Front Wheel Drive Automatic

How do I replase the transmission in a 2003
Mercury Sable?
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Friday, March 12th, 2010 AT 11:18 PM

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Tiny
BMRFIXIT
  • EXPERT
REMOVAL & INSTALLATION
WARNING:Vehicle is equipped with Supplemental Inflatable Restraint (SIR) system. When servicing vehicle, use care to avoid accidental air bag deployment. SIR system-related components are located in various locations throughout interior and exterior of vehicle, depending on application. Do not use electrical test equipment on or near these circuits. If necessary, deactivate SIR system before servicing components. See appropriate AIR BAG DEACTIVATION PROCEDURES article in GENERAL INFORMATION.

WARNING:On vehicles with electronic air suspension, power to air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. Failure to do so can result in inflation or deflation of air springs, which may cause vehicle to shift during servicing.

CAUTION:When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. Before disconnecting battery, see COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION.

TRANSAXLE (AX4S)
Removal
Remove the battery.
Disconnect the Mass Air Flow (MAF) sensor and the breather tubes.
Remove the engine air cleaner.
Remove the air filter assembly.
Disconnecting Mass Air Flow Sensor & Breather Tubes
Removing Engine Air Cleaner
Removing Air Filter Assembly
Remove the battery tray.
Disconnect the connectors.
Disconnect the connector.
Removing Battery Tray
Courtesy of FORD MOTOR CO.
Disconnecting Connectors
Disconnecting Connector

Remove the power steering line bracket.
Remove the electrical connector bracket.
Disconnect the power steering and Output Shaft Speed (OSS) sensor connectors.
Removing Power Steering Line Bracket
Removing Electrical Connector Bracket
Disconnecting Power Steering & Output Shaft Speed Sensor
Disconnect the Turbine Shaft Speed (TSS) sensor connector.
Remove the manual control lever cable as follows:
Remove the nut.
Remove the shift actuator cable fitting from the shift cable and bracket.
Remove the ground cable and bracket.
Disconnecting Turbine Shaft Speed Sensor
Removing Manual Control Lever Cable
Removing Ground Cable & Bracket
Remove the cooler line retaining clips.
Depress the tabs on the plastic insert retainer and remove the cooler lines from the fitting.
Remove the bolts. Removing Cooler Line Retaining Clips
Removing Cooler Lines From Fitting
Removing Bolts
Install the engine support tools.
Install the engine lifting bracket on the right hand (back) side of the engine.
Install the engine lifting bracket on the left hand (front) side of the engine.

Raise the vehicle. Drain the transaxle fluid by lowering the transaxle pan.
CAUTION:If the steering gear is removed with the subframe, DO NOT allow the steering wheel to rotate while the steering column intermediate shaft is disconnected or damage to the air bag clockspring can result. If there is evidence that the shaft has rotated, the clockspring must be re-centered before the vehicle is driven.

Remove the subframe assembly.
The use of mechanic's wire will aid in positioning the half shaft out of the way.
Using Slide Hammer (100-001) and Half Shaft Remover (205-241), remove the LH and RH half shaft from the transaxle and position out of the way.
Remove the starter motor.
Remove the transaxle housing cover.
Remove and discard the 4 torque converter to flexplate nuts. Removing Transaxle Housing Cover
Removing Flexplate Nuts

Remove the 2 transaxle retaining bolts..
Positioning Transaxle Jack
. Removing Transaxle Retaining Bolts

Remove the bolts..
Lower the transaxle assembly from the engine compartment.
Remove the rear engine support bracket.
Remove the bolts.
Remove the support bracket.
Remove the bracket..
Carry out transaxle fluid cooler backflushing and cleaning. See OIL COOLER BACK FLUSHING & CLEANING under LUBRICATION in SERVICING article.
Installation
Install the rear engine support bracket and bolts. Tighten to specification..
Install the bracket. Tighten to specification.
NOTE:Locate and align the orange dot adjacent to the stud on the torque converter and place it in the 6 o'clock position.

Install the transaxle.
Position the transaxle on a high lift transaxle jack.
Apply multi-purpose grease (ESB-M1C93-B) to the torque converter pilot hub.
Install the bolts. Tighten to specification.
Install the 2 transaxle retaining bolts. See Fig. 23. Tighten to specification. See TORQUE SPECIFICATIONS.
Install NEW torque to flexplate nuts. See Fig. 21. Tighten to specification. See TORQUE SPECIFICATIONS.
Install the transaxle housing cover. See Fig. 20. Tighten to specification. See TORQUE SPECIFICATIONS. Install the starter motor.
Install the LH half shaft.
Install the RH half shaft..
.
Install the subframe assembly.
Remove the special engine support tools. Install the bolts.. Tighten to specification. See TORQUE SPECIFICATIONS.
Reconnect the transaxle fluid cooler tubes.
Install the retaining clips.
Install the bracket and ground cable. Tighten to specification. See TORQUE SPECIFICATIONS.
Verify that the digital Transaxle Range (TR) sensor is correctly adjusted. See TRANSAXLE RANGE SENSOR under ADJUSTMENTS in SERVICING article.
Install the manual control lever cable and nut.
Install the manual control lever cable into the bracket.
Tighten the nut to specification. See TORQUE SPECIFICATIONS.
Reconnect the Turbine Shaft Speed (TSS) sensor connector.
Reconnect the power steering and Output Shaft Speed (OSS) sensor. See Fig. 9.
Install the electrical connector bracket.
Install the power steering line bracket.
Reconnect the connectors. Install the air filter assembly.
Install the engine air cleaner.
Reconnect the Mass Air Flow (MAF) sensor and the breather tubes. .
Install the battery. Fill the transaxle with clean automatic transaxle fluid. See RECOMMENDED FLUIDS and FLUID CAPACITIES under LUBRICATION in SERVICING article
Start the engine. Move the transaxle range selector lever through all positions. Check the fluid level. See CHECKING FLUID LEVEL & CONDITION under LUBRICATION in SERVICING article.
TRANSAXLE (4F50N)
Removal (3.0L/2V)
Remove the battery. Disconnect the Mass Air Flow (MAF) sensor and the breather tubes.
Remove the engine air cleaner. . Remove the air filter assembly. Remove the battery tray. . Disconnect the connectors. Disconnect the connector. . Remove the power steering line bracket. Remove the electrical connector bracket. . Disconnect the power steering and Turbine Shaft Speed (TSS) sensor connectors.
Disconnect the TSS sensor connector. See Fig. 10. Remove the manual control lever cable. Remove the nut. Remove the shift actuator cable fitting from the shift cable and bracket. See Fig. 11.
Remove the ground cable and bracket. See Fig. 12. Remove the cooler line retaining clips. See Fig. 13.
Depress the tabs on the plastic insert retainer and remove cooler lines from fitting. See Fig. 14. Remove the bolts. See Fig. 15.
Install the 3 bar engine support. See Fig. 16. Install the engine lifting bracket on the right (back) hand side of the engine. See Fig. 17.
Install the engine lifting bracket on the left (front) hand side of the engine. See Fig. 18.
Raise the vehicle. Drain the transaxle fluid by lowering the transaxle pan. Once the fluid has drained, re-install the pan. Remove the sub frame assembly. Using the Half Shaft Remover (205-241) and Slide Hammer (100-001), remove the RH and LH half shaft from the transaxle and position out of the way. See Fig. 19.
CAUTION:If the steering gear is removed with the subframe, do not allow the steering wheel to rotate while the steering column intermediate is disconnected or damage to the clockspring can result. If there is evidence that the shaft has rotated, the clockspring must be recentered before the vehicle is driven.

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

Remove the starter motor. Remove the transaxle housing cover. See Fig. 20. Remove and discard the four torque converter to flexplate nuts. See Fig. 21.
Position the high lift transaxle jack under the transaxle. See Fig. 22. Remove the transaxle retaining bolt. See Fig. 23.
Remove the transaxle retaining bolt. See Fig. 24. Remove the bolts. See Fig. 25.
Lower the transaxle assembly from the engine compartment. Remove the bolts. Remove the rear engine support bracket. See Fig. 26. Remove the bracket. See Fig. 27.
Carry out transaxle fluid cooler backflushing and cleaning. See OIL COOLER BACK FLUSHING & CLEANING under LUBRICATION in SERVICING article.
Installation
Install the rear engine support bracket and bolts. See Fig. 26. Tighten to specification. See TORQUE SPECIFICATIONS. Install the bracket. See Fig. 27. Tighten to specification. See TORQUE SPECIFICATIONS.
NOTE:Locate and align the orange dot adjacent to the stud on the torque converter and place it in the 6 o'clock position. Install the transaxle.

Position the transaxle on a High Lift jack. Apply Multi-Purpose Grease (D0AZ-19584-AA) meeting Ford specification ESB-M1C93-B or equivalent to the torque converter pilot hub. See Fig. 28.
Install the bolts. See Fig. 25. Tighten to specification. See TORQUE SPECIFICATIONS. Install the transaxle retaining bolts. See Fig. 23 and Fig. 24. Tighten to specification. See TORQUE SPECIFICATIONS.
Install NEW torque to flexplate nuts. Tighten to specification. See TORQUE SPECIFICATIONS. Install the transaxle housing cover. See Fig. 20. Tighten to specification. See TORQUE SPECIFICATIONS.
Install the starter motor. Install the LH and RH half shaft. See Fig. 29 and Fig. 30.
CAUTION:If the steering gear was removed with the subframe and there is evidence that the steering column intermediate shaft has rotated, the clockspring must be recentered before the vehicle is driven or damage to the clockspring can result.

Install the subframe assembly. Remove the LH and RH Engine Lifting Bracket. See Fig. 17 and Fig. 18.
Remove the engine support. See Fig. 16. Install the bolts. See Fig. 15. Tighten to specification. See TORQUE SPECIFICATIONS. Reconnect the transaxle fluid cooler tubes. See Fig. 14.
Install the retaining clips. See Fig. 13. Install the bracket and ground cable. See Fig. 12. Tighten to specification. See TORQUE SPECIFICATIONS.
Verify that the digital Transaxle Range (TR) sensor is correctly adjusted. See TRANSAXLE RANGE SENSOR under ADJUSTMENTS in SERVICING article.
Install the manual control lever cable and nut. Install the manual control lever cable into the bracket. See Fig. 11. Tighten the nut to specification. See TORQUE SPECIFICATIONS.
Reconnect the Turbine Shaft Speed (TSS) sensor connector. See Fig. 10. Reconnect the power steering and Output Shaft Speed (OSS) sensor. See Fig. 9.
Install the electrical connector bracket. See Fig. 8. Tighten to specification. See TORQUE SPECIFICATIONS. Install the power steering line bracket. See Fig. 7. Tighten to specification. See TORQUE SPECIFICATIONS.
Reconnect the connectors. See Fig. 5 and Fig. 6. Install the battery tray. See Fig. 4. Tighten to specification. See TORQUE SPECIFICATIONS. Install the air filter assembly. See Fig. 3.
Install the engine air cleaner. See Fig. 2. Reconnect the Mass Air Flow (MAF) sensor and the breather tubes. See Fig. 1.
Install the battery. Fill the transaxle using appropriate transaxle fluid. See RECOMMENDED FLUIDS and FLUID CAPACITIES under LUBRICATION in SERVICING article.
Start the engine. Move the transaxle range selector lever through all positions. Check the fluid level. See CHECKING FLUID LEVEL & CONDITION under LUBRICATION in SERVICING article.
Removal (3.0L/4V)
Remove the battery. Disconnect the Mass Air Flow (MAF) sensor.
Disconnect the breather tubes. Remove the engine air cleaner. Remove the air filter assembly.
Remove the battery tray. Disconnect the connectors.
Remove the electrical connector and the wiring harness from the bracket.
Remove the manual control lever cable. Remove the nut. Remove the shift actuator cable fitting from the shift cable and bracket.
Disconnect the power steering sensor connector.
Disconnect the power steering
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Tuesday, March 16th, 2010 AT 8:00 PM

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