Removal And Installation: Transaxle: Removal

All vehicles 

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
NOTE: Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent).
Fig 1: Holding Steering Wheel
Courtesy of FORD MOTOR CO.
2. Using a holding device, hold the steering wheel in the straight ahead position.
NOTE: It is not necessary to remove the Air Cleaner (ACL) outlet pipe from the ACL. Remove the ACL and the ACL outlet pipe as an assembly.
3. Remove the ACL assembly and ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
4. Remove the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
5. Disconnect the selector lever cable end from the manual control lever.
   Fig 2: Locating Selector Lever Cable End

   Courtesy of FORD MOTOR CO.
6. Release the 2 tabs, remove the selector lever cable from the selector lever cable bracket and position the cable aside.
   Fig 3: Locating Selector Lever Cable Tabs And Bracket

   Courtesy of FORD MOTOR CO.
7. Remove the starter motor electrical terminal cover.
   Fig 4: Locating Starter Motor Electrical Terminal Cover

   Courtesy of FORD MOTOR CO.
8. Disconnect the wiring harness fastener from the starter motor studbolt.
   Fig 5: Locating Starter Motor Stud Bolt

   Courtesy of FORD MOTOR CO.
9. Remove the rear starter motor stud bolt.
   Fig 6: Locating Starter Studbolt

   Courtesy of FORD MOTOR CO.
NOTE: Do not use tools with sharp edges to remove the fuel supply tube or the fuel vapor tube from the retainer. Tools with sharp edges can damage the tubes causing a fuel leak.
NOTE: Note the position and orientation of the fuel tubes in the retainer for assembly. The fuel vapor tube is in the top groove of the retainer and the fuel supply tube is in the bottom groove of the retainer.
10. Carefully compress the retaining tabs of the fuel tube retainer and remove the fuel supply and fuel vapor tubes from the fuel tube retainer.
    1. Retaining tabs
    2. Fuel vapor tube
    3. Fuel supply tube
       Fig 7: Removing Fuel Supply And Fuel Vapor Tubes From Fuel Tube Retainer

       Courtesy of FORD MOTOR CO.
11. Disconnect the transaxle electrical connector.
    Fig 8: Locating Transaxle Electrical Connector

    Courtesy of FORD MOTOR CO.
12. Remove the top 4 torque converter housing bolts.
    Fig 9: Locating Top Torque Converter Housing Bolts

    Courtesy of FORD MOTOR CO.
13. Install the Engine Lifting Bracket on the LH cylinder head.
    Fig 10: Locating Engine Lifting Bracket On LH Cylinder Head

    Courtesy of FORD MOTOR CO.
14. Remove the upper intake manifold. For additional information, refer to ENGINE - 3.5L .
15. Install the Engine Support Bar and Engine Spreader Bar to support the engine.
    Fig 11: Identifying Engine Support Bar And Engine Spreader Bar

    Courtesy of FORD MOTOR CO.
16. Remove the transaxle support insulator through bolt.
    Fig 12: Locating Transaxle Support Insulator Through Bolt

    Courtesy of FORD MOTOR CO.
17. Remove the 3 nuts, the bolt and the transaxle support insulator bracket.
    Fig 13: Locating Transaxle Support Insulator Bracket Bolts And Nuts

    Courtesy of FORD MOTOR CO.
18. Position aside the RH fender splash shield.
    1. Remove the screws.
    2. Remove the pushpin fasteners.
       Fig 14: Identifying RH Fender Splash Shield Screws And Pushpin Fasteners

       Courtesy of FORD MOTOR CO.
19. Remove the pushpin fasteners, the screws and the front splash shield.
    Fig 15: Locating Front Splash Shield, Pushpin Fasteners And Screws

    Courtesy of FORD MOTOR CO.
20. Remove the 3 RH subframe-to-lower bumper nuts.
    Fig 16: Locating RH Subframe-To-Lower Bumper Nuts

    Courtesy of FORD MOTOR CO.
21. Remove the 3 LH subframe-to-lower bumper nuts and separate the front support from the subframe.
    Fig 17: Locating LH Subframe-To-Lower Bumper Nuts

    Courtesy of FORD MOTOR CO.
22. Disconnect the power steering cooler hose and drain the power steering fluid into a drain pan.
    Fig 18: Locating Power Steering Cooler Hose Clamp

    Courtesy of FORD MOTOR CO.
23. Remove the power steering cooler bracket bolt from the RH side of the subframe.
    Fig 19: Locating Power Steering Cooler Bracket Bolt

    Courtesy of FORD MOTOR CO.
24. Remove the transmission fluid drain plug and allow the transmission fluid to drain.
    Fig 20: Locating Transmission Fluid Drain Plug

    Courtesy of FORD MOTOR CO.
25. Install the transmission fluid drain plug.
    • Tighten to 9 Nm (80 lb-in).
      Fig 21: Locating Transmission Fluid Drain Plug

      Courtesy of FORD MOTOR CO.
NOTE: It is not necessary to separate the RH halfshaft from the intermediate shaft when removing the intermediate shaft. Remove the intermediate shaft and the RH halfshaft as an assembly.
26. Remove the LH front halfshaft and the intermediate shaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
NOTE: LH halfshaft shown in illustration, RH halfshaft similar.
27. Inspect the halfshaft hubs for wear or damage and replace the halfshaft(s), if necessary.
    1. Inspect the differential seal surface.
    2. Inspect the halfshaft bushing surface. If this surface is damaged, inspect the halfshaft bushing for damage.
    3. Inspect the differential side gear splines.
       Fig 22: Identifying Differential Seal, Halfshaft Bushing Surface And Differential Side Gear Splines

       Courtesy of FORD MOTOR CO.
28. Remove the exhaust Y-pipe. For additional information, refer to EXHAUST SYSTEM .
29. Remove and discard the Power Steering Pressure (PSP) tube-to-steering gear banjo bolt and the 2 seals.
    Fig 23: Locating Power Steering Pressure Tube-To-Steering Gear Banjo Bolt And Seals

    Courtesy of FORD MOTOR CO.
NOTE: 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 .
30. Remove and discard the steering intermediate shaft bolt.
    • Separate the steering intermediate shaft from the steering gear.
      Fig 24: Separating Steering Intermediate Shaft From Steering Gear

      Courtesy of FORD MOTOR CO.
NOTE: RH shown in illustration, LH similar.
31. Remove and discard the cotter pins and tie-rod end nuts.
    • Using the Tie-Rod End Remover, separate the tie-rod ends from the wheel knuckles.
      Fig 25: Separating Tie-Rod Ends From Wheel Knuckles Using Tie-Rod End Remover

      Courtesy of FORD MOTOR CO.
32. Remove the 2 nuts and the roll restrictor heat shield.
    Fig 26: Locating Roll Restrictor Heat Shield Nuts

    Courtesy of FORD MOTOR CO.
33. Remove the 2 roll restrictor through bolts and the roll restrictor.
    Fig 27: Locating Roll Restrictor Through Bolts

    Courtesy of FORD MOTOR CO.
34. With a wax pencil, mark the relationship of the front subframe to the underbody at the mounting locations.
35. Support the subframe using the Powertrain Lift With Tilting Plate.
36. Remove the 2 nuts, 4 bolts and the subframe support brackets.
    Fig 28: Locating Subframe Support Brackets, Nuts And Bolts

    Courtesy of FORD MOTOR CO.
37. Remove the 2 front subframe nuts.
    Fig 29: Locating Front Subframe Nuts

    Courtesy of FORD MOTOR CO.
38. Remove the 2 middle subframe nuts and remove the subframe.
    Fig 30: Locating Middle Subframe Nut

    Courtesy of FORD MOTOR CO.
39. Remove the 3 bolts and the roll restrictor bracket.
    Fig 31: Locating Roll Restrictor Bracket Bolts

    Courtesy of FORD MOTOR CO.

    All-Wheel Drive (AWD) vehicles 

40. Index-mark the driveshaft, remove the 4 bolts and position the driveshaft aside.
    Fig 32: Locating Driveshaft Bolts

    Courtesy of FORD MOTOR CO.
41. Disconnect the RH catalyst monitor electrical connector.
    Fig 33: Locating RH CMS Electrical Connector

    Courtesy of FORD MOTOR CO.
42. Remove the 4 RH catalytic converter nuts and the RH catalytic converter.
    Fig 34: Locating RH Catalytic Converter Nuts

    Courtesy of FORD MOTOR CO.
43. Remove the 5 bolts and the Power Transfer Unit (PTU) support bracket.
    Fig 35: Locating PTU Support Bracket Bolts

    Courtesy of FORD MOTOR CO.
44. Remove the 5 bolts and the PTU.
    Fig 36: Locating Power Transfer Unit Bolts

    Courtesy of FORD MOTOR CO.

    All vehicles 

45. Remove the 2 fasteners and the inspection cover.
    Fig 37: Locating Inspection Cover

    Courtesy of FORD MOTOR CO.
46. Remove and discard the 3 torque converter bolts.
    Fig 38: Locating Torque Converter Bolt

    Courtesy of FORD MOTOR CO.
47. Remove the 2 transmission fluid cooler tube secondary latches from the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.
    Fig 39: Locating Transmission Fluid Cooler Tube Secondary Latches

    Courtesy of FORD MOTOR CO.
48. Using the Transmission Cooler Line Disconnect Tool, disconnect the transmission fluid cooler tubes from the transmission fluid cooler thermal bypass valve.
    Fig 40: Disconnecting Transmission Fluid Cooler Tubes From Transmission Fluid Cooler Thermal Bypass Valve

    Courtesy of FORD MOTOR CO.
49. Using the Transmission Jack Adapter and a transmission jack, support the transaxle.
    Fig 41: Identifying Transmission Jack Adapter

    Courtesy of FORD MOTOR CO.
50. Remove the 7 torque converter housing bolts and remove the transaxle from the vehicle.
    Fig 42: Locating Torque Converter Housing Bolts

    Courtesy of FORD MOTOR CO.
51. Inspect the torque converter housing mating surface to make sure that the dowel pins did not come out of the engine block when the transaxle was removed. If the dowel pin is stuck in the torque converter housing, remove the dowel pin from the torque converter housing.
    Fig 43: Locating Torque Converter Housing Dowel Pins

    Courtesy of FORD MOTOR CO.
52. Remove and discard the fuel tube retainer from the transaxle studbolt.
    Fig 44: Locating Fuel Tube Retainer

    Courtesy of FORD MOTOR CO.
53. Remove the nut and the manual control lever.
    Fig 45: Locating Manual Control Lever And Nut

    Courtesy of FORD MOTOR CO.
54. Remove and discard the transmission fluid cooler tube bolts.
    Fig 46: Locating Transmission Fluid Cooler Tube Bolt

    Courtesy of FORD MOTOR CO.
55. Remove the 2 transmission fluid cooler thermal bypass valve bracket nuts, pull the transmission fluid cooler thermal bypass valve and the transmission fluid cooler tubes straight up and remove the assembly from the transaxle.
    Fig 47: Pulling Transmission Fluid Cooler Thermal Bypass Valve

    Courtesy of FORD MOTOR CO.
56. Inspect the transaxle case to make sure that the transmission fluid cooler tube seals and backing rings were removed with the transmission fluid cooler tubes and are not stuck in the transaxle case. If the transmission fluid cooler tube seals or backing rings are stuck in the transaxle case, remove the seals and backing rings.
    Fig 48: Locating Transmission Fluid Cooler Tube Seal

    Courtesy of FORD MOTOR CO.
57. If the transaxle is to be overhauled or if installing a new transaxle, carry out transmission fluid cooler backflushing and cleaning. For additional information, refer to TRANSMISSION FLUID COOLER BACKFLUSHING AND CLEANING .