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Engine - Automatic Transaxle

WARNING: This page is about a different car, the 2006 Mercury Milan and 2006 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL DESCRIPTION

G04680131Courtesy of FORD MOTOR CO.
 Separator, Balljoint
205-592
G04680132Courtesy of FORD MOTOR CO.
 Adapter for
204-592 204-592/1
G04680133Courtesy of FORD MOTOR CO.
 Tie-Rod End Remover
211-105
G04680134Courtesy of FORD MOTOR CO.
 Heavy Duty Floor Crane
014-00071 or equivalent
G04680135Courtesy of FORD MOTOR CO.
 Spreader Bar
303-D089 (D93P-6001-A3) or equivalent
G04680136Courtesy of FORD MOTOR CO.
 Powertrain Lift
014-00765
G04680137Courtesy of FORD MOTOR CO.
 Universal Adapter Brackets 014-0001
Lifting Bracket Set, Engine
303-D095 (D94L-6001-A) or equivalent
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. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  3. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  4. Recover the air conditioning system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS
  5. Place the steering wheel in the straight ahead position and the ignition key in the OFF position.
  6. Remove the 2 nuts and the steering joint cover.
    Fig 1: Locating Steering Joint Cover And Nuts
    G04680138Courtesy of FORD MOTOR CO.
    7. CAUTION: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring can occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to SUPPLEMENTAL RESTRAINT SYSTEM .
    NOTE: Index the steering column shaft position to the steering gear for reference during installation.
    Fig 2: Locating Steering Column Shaft Bolt
    G04680139Courtesy of FORD MOTOR CO.
  7. Remove the bolt and disconnect the steering column shaft from the steering gear.
  8. Remove the bolt and disconnect the power steering pressure (PSP) tube from the power steering pump.
    • Route the PSP tube out the bottom of the engine compartment.
      Fig 3: Locating Bolt
      G04680140Courtesy of FORD MOTOR CO.
  9. Drain the cooling system. For additional information, refer to ENGINE COOLING .
  10. If equipped, remove the 7 screws and the underbody cover.
    Fig 4: Locating Underbody Cover Screws
    G04680141Courtesy of FORD MOTOR CO.
  11. Remove the exhaust flexible pipe. For additional information, refer to EXHAUST SYSTEM .
    12. CAUTION: The steering gear-to-dash seal must be removed or it will be damaged when lowering the subframe.
    Fig 5: Locating Clips
    G04680142Courtesy of FORD MOTOR CO.
  12. Release the 4 clips and slide the steering gear-to-dash seal off of the steering gear and into the passenger compartment.
  13. Remove the engine roll restrictor bolt.
    Fig 6: Locating Engine Roll Restrictor Bolt
    G04680143Courtesy of FORD MOTOR CO.
  14. Remove the 4 screws and position the RH fender splash shield aside.
    Fig 7: Locating RH Fender Splash Shield Screws
    G04684102Courtesy of FORD MOTOR CO.
  15. Remove the 6 pin-type retainers (4 shown) and the RH splash shield.
    Fig 8: Locating Splash Shield Pin-Type Retainers
    G04684103Courtesy of FORD MOTOR CO.
  16. Remove the 4 screws and position the LH fender splash shield aside.
    Fig 9: Locating LH Fender Splash Shield Screws
    G04680146Courtesy of FORD MOTOR CO.
  17. Remove the 6 pin-type retainers (4 shown) and the LH splash shield.
    Fig 10: Locating Pin-Type Retainers And LH Splash Shield
    G04680147Courtesy of FORD MOTOR CO.
    18. NOTE: LH shown, RH similar.
    Fig 11: Locating Tie-Rod Ends Cotter Pins And Nuts
    G04680148Courtesy of FORD MOTOR CO.
  18. Remove the cotter pins and nuts from the tie-rod ends.
    19. NOTE: LH shown, RH similar.
    Fig 12: Identifying Special Tool
    G04680149Courtesy of FORD MOTOR CO.
  19. Using the special tool, separate the tie-rod ends from the steering knuckles.
  20. Disconnect the power steering cooler tube.
    Fig 13: Locating Power Steering Cooler Tube
    G04680150Courtesy of FORD MOTOR CO.
    21. NOTE: LH shown, RH similar.
    Fig 14: Locating Sway Bar Links Nut
    G04680151Courtesy of FORD MOTOR CO.
  21. Remove the nuts and separate the sway bar links from the struts.
    22. NOTE: LH shown, RH similar.
    Fig 15: Locating Lower Ball Joint Nuts
    G04680152Courtesy of FORD MOTOR CO.
  22. Remove the lower ball joint nuts.
    23. CAUTION: When the lower ball joint is separated from the wheel knuckle, the lower arm may strike the outer constant velocity (CV) joint boot with enough force to damage the boot clamp. This will result in a loss of grease from the outer CV joint. Place a block of wood, or similar item, between the lower arm and the outer CV joint to prevent the lower arm from striking the outer CV joint.
    NOTE: Once pressure is applied to the ball joint with the special tool, it may be necessary to tap the wheel knuckle at the ball joint area to separate the ball joint from the wheel knuckle.
    NOTE: LH shown, RH similar.
    Fig 16: Identifying Special Tools
    G04680153Courtesy of FORD MOTOR CO.
  23. Using the special tools, separate the lower ball joints from the lower control arms.
    24. NOTE: LH shown, RH similar.
    Fig 17: Locating Lower Control Arms Through Bolt
    G04680154Courtesy of FORD MOTOR CO.
  24. Remove the through bolts from the lower control arms.
  25. Position the special tool under the subframe assembly.
    Fig 18: Identifying Special Tool
    G04680155Courtesy of FORD MOTOR CO.
    26. NOTE: LH shown, RH similar.
    Fig 19: Locating Subframe Bracket-To-Body Bolts
    G04680156Courtesy of FORD MOTOR CO.
  26. Remove the subframe bracket-to-body bolts.
    27. NOTE: LH shown, RH similar.
    Fig 20: Locating Subframe Nuts
    G04680157Courtesy of FORD MOTOR CO.
  27. Remove the subframe nuts and the subframe brackets.
    28. NOTE: LH shown, RH similar.
    Fig 21: Locating Front Subframe Nuts
    G04680158Courtesy of FORD MOTOR CO.
  28. Remove the front subframe nuts.
  29. Lower the subframe assembly from the vehicle.
  30. Remove the engine oil pan drain plug and drain the engine oil.
    • Install the drain plug and tighten to 28 Nm (21 lb-ft).
      Fig 22: Locating Drain Plug
      G04680159Courtesy of FORD MOTOR CO.
  31. Remove the oil filter element. For additional information, refer to ENGINE LUBRICATION COMPONENTS - EXPLODED VIEW  and OIL FILTER ELEMENT .
  32. Remove the bolt, 2 nuts and the generator air inlet duct.
    Fig 23: Locating Bolt, Nuts And Generator Air Inlet Duct
    G04680160Courtesy of FORD MOTOR CO.
  33. Remove the engine air cleaner and air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING - 2.3L .
  34. Remove the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  35. Remove the nut and disconnect the wire from the battery cable.
    Fig 24: Locating Battery Cable And Nut
    G04680161Courtesy of FORD MOTOR CO.
  36. Disconnect the 2 engine wiring harness electrical connectors.
    Fig 25: Locating Electrical Connectors
    G04680162Courtesy of FORD MOTOR CO.
  37. Remove the bolt and the ground wire.
    Fig 26: Locating Ground Wire And Bolt
    G04680163Courtesy of FORD MOTOR CO.
  38. Disconnect the powertrain control module (PCM) electrical connector and the pin-type retainer.
    Fig 27: Locating Pin-Type Retainer And Powertrain Control Module (PCM) Electrical Connector
    G04680164Courtesy of FORD MOTOR CO.
  39. Disconnect the fuel supply tube from the fuel rail. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  40. Disconnect the crankcase vent tube from the valve cover.
    Fig 28: Locating Crankcase Vent Tube
    G04680165Courtesy of FORD MOTOR CO.
  41. Depress the locking ring and disconnect the brake booster vacuum supply tube from the intake manifold.
    Fig 29: Locating Locking Ring And Brake Booster Vacuum Supply Tube
    G04680166Courtesy of FORD MOTOR CO.
  42. Disconnect the evaporative emissions (EVAP) tube from the intake manifold.
    Fig 30: Locating Evaporative Emissions (EVAP) Tube From Intake Manifold
    G04680167Courtesy of FORD MOTOR CO.
  43. Detach the retaining clip and position the EVAP tube bundle aside.
    Fig 31: Locating Retaining Clip
    G04680168Courtesy of FORD MOTOR CO.
  44. Disconnect the upper radiator and heater hoses from the coolant bypass.
    Fig 32: Locating Upper Radiator And Heater Hoses
    G04680169Courtesy of FORD MOTOR CO.
  45. If equipped, disconnect the block heater electrical connector and detach the harness retaining clips from the heater hose.
    Fig 33: Locating Heater Hose Retaining Clips
    G04680170Courtesy of FORD MOTOR CO.
  46. Disconnect the heater hose inline connector.
    Fig 34: Locating Heater Hose Inline Connector
    G04680171Courtesy of FORD MOTOR CO.
  47. Disconnect the transaxle control cable from the control lever.
    • Detach the control cable from the bracket.
      Fig 35: Locating Transaxle Control Cable From Control Lever
      G04680172Courtesy of FORD MOTOR CO.
  48. Disconnect the transaxle cooler tubes.
    Fig 36: Locating Transaxle Cooler Tubes
    G04680173Courtesy of FORD MOTOR CO.
  49. Remove the bolt and position the radio frequency interference capacitor and ground wire aside.
    Fig 37: Locating Bolt, Radio Frequency Interference Capacitor And Ground Wire
    G04680174Courtesy of FORD MOTOR CO.
  50. Detach the coolant vent hose retaining clip from the A/C tube.
    Fig 38: Locating Coolant Vent Hose Retaining Clip
    G04680175Courtesy of FORD MOTOR CO.
  51. Disconnect the power steering cooler tube.
    Fig 39: Locating Power Steering Cooler Tube
    G04680176Courtesy of FORD MOTOR CO.
  52. Remove the 2 A/C tube bracket bolts.
    Fig 40: Locating A/C Tube Bracket Bolts
    G04680177Courtesy of FORD MOTOR CO.
  53. Remove the 2 nuts and disconnect the A/C tubes.
    Fig 41: Locating A/C Tubes Nuts
    G04680178Courtesy of FORD MOTOR CO.
  54. Remove the nut and disconnect the A/C tube from the condenser.
    Fig 42: Locating A/C Tubes Nut
    G04680179Courtesy of FORD MOTOR CO.
  55. Remove the bolt and the radio frequency interference capacitor from the engine mount bracket.
    Fig 43: Locating Radio Frequency Interference Capacitor Bolt
    G04680180Courtesy of FORD MOTOR CO.
  56. Remove the retaining clip and disconnect the lower radiator hose.
    Fig 44: Removing Retaining Clip And Identifying Lower Radiator Hose
    G04680181Courtesy of FORD MOTOR CO.
  57. Using a suitable tool, separate the LH halfshaft from the transaxle and support the halfshaft with a length of mechanic's wire.
  58. Remove the 2 RH halfshaft carrier bearing bracket bolts.
    Fig 45: Locating RH Halfshaft Carrier Bearing Bracket Bolts
    G04680182Courtesy of FORD MOTOR CO.
  59. Separate the RH halfshaft from the transaxle and support the halfshaft with a length of mechanic's wire.
    Fig 46: Locating RH Halfshaft
    G04680183Courtesy of FORD MOTOR CO.
  60. Remove the bellhousing-to-oil pan bolt.
    Fig 47: Locating Bellhousing-To-Oil Pan Bolt
    G04680184Courtesy of FORD MOTOR CO.
  61. Remove the 2 oil pan-to-bellhousing bolts.
    Fig 48: Locating Oil Pan-To-Bellhousing Bolts
    G04680185Courtesy of FORD MOTOR CO.

    62. Vehicles with secondary air injection (AIR) 

  62. Disconnect the AIR pump electrical connector.
    Fig 49: Locating AIR Pump Electrical Connector
    G04680186Courtesy of FORD MOTOR CO.
  63. Remove the 3 bolts and position the AIR pump aside.
    Fig 50: Locating AIR Pump Bolts
    G04680187Courtesy of FORD MOTOR CO.

    64. All vehicles 

    NOTE: Position a suitable block of wood under the transaxle.
  64. Install the special tools onto the engine.
    • Raise the engine and transaxle 25.4 mm (1 in) to neutralize the engine and transaxle mounts.
      Fig 51: Identifying Special Tools
      G04680188Courtesy of FORD MOTOR CO.
  65. Remove the 2 transaxle mount bolts.
    Fig 52: Locating Transaxle Mount Bolts
    G04680189Courtesy of FORD MOTOR CO.
  66. Remove the bolt, 2 nuts and the engine mount bracket.
    Fig 53: Locating Engine Mount Bracket Bolt And Nuts
    G04680190Courtesy of FORD MOTOR CO.
  67. Lower the engine and transaxle from the vehicle.
  68. Remove the 2 nuts and disconnect the starter wires.
    Fig 54: Locating Starter Wire Nuts
    G04680191Courtesy of FORD MOTOR CO.
  69. Detach the 2 wiring harness retainers from the starter stud bolts.
  70. Remove the 2 stud bolts and the starter.
    Fig 55: Locating Starter Stud Bolts
    G04680192Courtesy of FORD MOTOR CO.
  71. Remove the 4 torque convertor nuts.
    Fig 56: Locating Torque Convertor Nuts
    G04680193Courtesy of FORD MOTOR CO.
  72. Remove the bolt and ground wire.
    Fig 57: Locating Ground Wire Bolt
    G04680194Courtesy of FORD MOTOR CO.
  73. Remove the nut and position the engine wiring harness bracket aside.
    Fig 58: Locating Engine Wiring Harness Bracket And Nut
    G04680195Courtesy of FORD MOTOR CO.
  74. Disconnect the transmission range (TR) sensor and primary control solenoid electrical connectors.
    Fig 59: Locating Transmission Range (TR) Sensor And Primary Control Solenoid Electrical Connectors
    G04680196Courtesy of FORD MOTOR CO.
  75. Disconnect the transaxle control electrical connectors.
    Fig 60: Locating Transaxle Control Electrical Connectors
    G04680197Courtesy of FORD MOTOR CO.
  76. Disconnect the turbine shaft speed (TSS) sensor electrical connector.
    Fig 61: Locating Turbine Shaft Speed (TSS) Sensor Electrical Connector
    G04680198Courtesy of FORD MOTOR CO.
  77. Disconnect the output shaft speed (OSS) sensor electrical connector.
    Fig 62: Locating Output Shaft Speed (OSS) Sensor Electrical Connector
    G04680199Courtesy of FORD MOTOR CO.
  78. Disconnect the transaxle pressure switch electrical connector.
    Fig 63: Locating Transaxle Pressure Switch Electrical Connector
    G04680200Courtesy of FORD MOTOR CO.
  79. Install the special tools and remove the engine and transaxle from the powertrain lift table.
    Fig 64: Identifying Special Tools
    G04680201Courtesy of FORD MOTOR CO.
  80. Remove the bellhousing-to-engine retainers.
    • Separate the engine and transaxle.
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