Section 249 (Engine - 2.7L ECOBOOST (238KW/324PS)): Removal: Engine

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	303-1246 Engine Spreader Bar TKIT-2006UF-FLM TKIT-2006UF-ROW
Courtesy of FORD MOTOR COMPANY	303-1634 Lift Eyes (2) TKIT-2014D-FL_ROW TKIT-2014D-ROW3
Courtesy of FORD MOTOR COMPANY	307-346 (T97T-7902-A) Retainer, Torque Converter TKIT-1997-F/FLM/LT TKIT-1998-LM (NavigatoR)
Courtesy of FORD MOTOR COMPANY	307-569 Disconnect Tool TOC Line (1/2) TKIT-2006U-F/FM TKIT-2006U-FLM/LM TKIT-2006U-ROW1 TKIT-2006U-ROW2
Tie Rod End Remover
Floor Crane
Adjustable Mounting Arm
Oil Drain Equipment
Cable Ties
Hose Clamp Remover/Installer
Powertrain Jack
Wooden Block

2WD/4WD 

1. With the vehicle in NEUTRAL, position it on a hoist. Refer to: Jacking and Lifting - Overview .
2. Evacuate the A/C system. Refer to: Air Conditioning (A/C) System Recovery, Evacuation And Charging .
3. Release the fuel pressure. Refer to: Fuel System Pressure Release .
4. NOTE: Use a steering wheel holding device (such as Hunter ® 28-75-1 or equivalent).

   Using a suitable holding tool, hold the steering wheel in the straight-ahead position.

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5. 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. Refer to Supplemental Restraint System .
   • Remove and discard the steering intermediate shaft bolt.
   • Separate the steering intermediate shaft from the steering gear.

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6. Remove the retainers and the upper air deflector.

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7. NOTE: Make sure the cooling module is secure before removing the bottom cooling module support panel.
   1. Remove the upper cooling module support brackets.
   2. Using cable ties or mechanics wire through the upper location holes, to support the cooling module. Use the General Equipment: Cable Ties

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8. Remove the front wheels and tires. Refer to: Wheel and Tire .
9. Remove the retainers and the underbody shield.

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10. Remove the retainers and the front underbody shield.

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11. If equipped, remove the retainers and the underbody shield.

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12. Remove the retainers and the underbody shields.

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13. Drain the engine cooling system. Refer to: Cooling System Draining, Vacuum Filling And Bleeding .
14. 1. Remove the nut.
    2. Remove the bolt.
    • Remove the engine appearance cover.

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15. Remove the following items:
    1. Refer to: Degas Bottle .
    2. Refer to: Air Cleaner .
    3. Refer to: Air Cleaner Outlet Pipe LH .
    4. Refer to: Air Cleaner Outlet Pipe RH .
    5. Refer to: Charge Air Cooler (CAC) Intake Pipe .
    6. Refer to: Charge Air Cooler (CAC) Outlet Pipe .
    7. Refer to: Accessory Drive Belt .
    8. Refer to: Battery Tray .

16. Remove the stud bolt and position aside the ground cable.

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17. 1. Release the tabs.
    2. Lift and position top part of junction box aside.

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18. Release the tab and open cover.

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19. Remove the nuts and disconnect the electrical connector.

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20. Remove the bolt and detach the wiring harness retainers.

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21. Disconnect the vacuum tube quick release couplings and position the tube aside. Refer to: Quick Release Coupling .

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22. 1. Detach the cable from the transmission control lever.
    2. Remove the bolt and position the cable aside.

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23. 1. Detach the heater hose retainer.
    2. Loosen the radiator hose clamp.
    3. Lift the radiator hose off of the retaining tab and position the hose aside.

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24. 1. Release the clamp and disconnect the lower radiator hose. Use the General Equipment: Hose Clamp Remover/Installer
    2. Release the clamp and disconnect the heater hose. Use the General Equipment: Hose Clamp Remover/Installer
    3. Detach the heater hose retainer.
    4. Remove the bolt and position the heater hose aside.

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25. 1. Remove the ground wire bolt.
    2. Detach the retainers and position the ground wire aside.

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26. • Disconnect the engine harness electrical connector and retainer.
    • Disconnect the PCM electrical connector.

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27. 1. Disconnect the high-pressure fuel pump fuel feed tube quick release coupling. Refer to: Quick Release Coupling .
    2. Disconnect the EVAP tube quick release coupling. Refer to: Quick Release Coupling .

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28. Detach the retainer and position the wiring harness aside.

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29. NOTE: Use a shop towel when removing the oil filter housing to prevent oil from spilling on the engine or accessory drive belt.
    1. Loosen the oil filter housing and allow the oil to drain out of the housing and down into the engine.
    2. Remove the oil filter housing and discard the oil filter element.
    3. Remove and discard the O-ring seals.

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30. Remove the transmission fluid cooler tube secondary latches.

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31. Using the special tool, disconnect the transmission fluid cooler tubes from the transmission fluid cooler thermal bypass valve. Use Special Service Tool: 307-569 Disconnect Tool TOC Line (1/2).

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32. Detach and disconnect the engine harness electrical connector.

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33. Remove the RH front suspension height sensor. Refer to: Front Suspension Height Sensor .
34. Remove the generator nut.

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35. 1. Detach the wiring harness retainer.
    2. Position the A/C line bracket from the generator stud.

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36. Detach the wiring harness retainers, slide up the insulator and disconnect the electrical connectors.

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37. Remove the A/C compressor inlet and outlet line nuts and disconnect the fittings.
    • Discard the O-ring seals and gaskets.

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38. Remove the bolts, stud bolt and the A/C compressor.

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39. 1. Turn the oil drain plug counterclockwise 120 degrees. Use the General Equipment: Oil Drain Equipment
    2. Pull the oil drain plug out of the oil pan.
    3. After the oil has drained, push the oil drain plug into the oil pan.
    4. NOTE: Overtightening will damage the oil drain plug.

       Turn the oil drain plug clockwise 120 degrees.

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40. Remove the bolt and the LH anti-lock sensor.

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41. NOTE: Use the internal or external hex-holding feature to prevent the ball and stud from turning while removing or installing the stabilizer bar link nuts. The link boot seal must not be allowed to twist while tightening the link nuts or damage to the boot seal will occur.

    Remove the nut and position the LH sway bar link aside.

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42. NOTE: Use the internal or external hex-holding feature to prevent the ball and stud from turning while removing or installing the stabilizer bar link nuts. The link boot seal must not be allowed to twist while tightening the link nuts or damage to the boot seal will occur.

    Remove the nut and position the RH sway bar link aside.

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43. 1. Remove and discard the outer tie rod end nut.
    2. NOTE: Do not use a hammer to separate the outer tie-rod end from the wheel spindle or damage to the wheel spindle may result.
       NOTE: Use care when installing the tie rod end remover or damage to the outer tie-rod end boot may occur.

       Separate the outer tie rod end from the wheel knuckle. Use the General Equipment: Tie Rod End Remover

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44. Remove the following items:
    1. RH front halfshaft. Refer to: Front Halfshaft RH - FWD . Refer to: Front Halfshaft RH - 2.7L EcoBoost (238kW/324PS), All-Wheel Drive (AWD) .
    2. NOTE: Do not allow the brake caliper and anchor plate assembly to hang from the brake hose or damage to the hose can occur.

       Remove the LH brake disc. Refer to: Brake Disc .

45. Remove the nuts and the subframe support bracket.

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46. Remove the following items:
    1. Exhaust flexible pipes. Refer to: Exhaust Flexible Pipe .
    2. LH catalytic convertor. Refer to: Catalytic Converter LH .

    4WD 

47. Remove the driveshaft. Refer to: Rear Driveshaft .
48. Loosen the PTU bolts 19 mm (0.75 in).

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    2WD/4WD 

49. Mark the subframe location.

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50. Mark the subframe location.

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51. NOTE: The boards must be positioned to properly support the engine, transmission and subframe, and allow clearance between the powertrain jack and the exhaust components to prevent damage.

    Position lengths of 2 x 6 boards on the powertrain jack to support the oil pan, transmission and subframe. Use the General Equipment: Powertrain Jack Use the General Equipment: Wooden Block

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52. NOTE: View from rear of vehicle.

    Position the powertrain jack and boards under the engine, transmission and subframe. Use the General Equipment: Powertrain Jack Use the General Equipment: Wooden Block

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53. Remove the engine-to-transmission bolt.

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54. 1. Position the powertrain jack and boards under the powertrain and subframe. Use the General Equipment: Powertrain Jack Use the General Equipment: Wooden Block
    2. Install. Use the General Equipment: Adjustable Mounting Arm

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55. Remove and discard the nuts and the bolts.
    • Separate the LH knuckle from the strut.

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56. NOTE: The engine mount and bracket are serviced as an assembly. Do not remove the engine mount bracket-to-engine mount bolt, this fastener is not serviceable.
    • Remove and discard the nuts and bolts.
    • Remove the engine mount and bracket assembly.

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57. Remove and discard the transmission mount bolts.

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58. 1. Remove and discard the subframe bolts.
    2. Remove the bolts and the subframe brackets.

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59. Remove and discard the subframe bolts.

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60. Using the powertrain jack, lower the powertrain and subframe as an assembly. Use the General Equipment: Powertrain Jack

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61. Disconnect the RH HO2S and RH catalyst monitor sensor electrical connectors.

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62. 1. Loosen.
    2. Remove.

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63. 1. Remove and discard the RH catalytic converter nuts.
    2. Remove the RH catalytic converter.

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64. Remove and discard the RH catalytic converter gasket.

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65. 1. Lift up the generator cable protective cover.
    2. Remove the nut and disconnect the generator cable.
    3. Disconnect the generator electrical connector.

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66. Detach the wiring harness retainers.

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67. • Detach the wiring harness retainer.
    • If equipped, detach the PTU vent hose retainer.

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68. • Disconnect the transmission electrical connector.
    • Detach the wiring harness retainers.

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69. 1. Lift up the starter cable protective cover.
    2. Remove the nut and disconnect the starter cable.
    3. Disconnect the starter electrical connector.
    4. Detach the wiring harness retainers.

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70. Remove the nuts and the bracket.

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71. Remove the stud bolts and the starter.

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72. Remove the retainers and the access cover.

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73. NOTE: Using the crankshaft pulley bolt, turn the engine clockwise.

    Remove and discard the torque converter nuts.

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    4WD 

74. Remove the bolts and the heat shield.

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75. Remove the bolts and the bracket.

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76. Loosen the PTU bolts 19 mm (0.75 in).

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77. Separate the PTU from the transmission 19 mm (0.75 in).

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    2WD/4WD 

78. 1. Install Special Service Tool: 303-1634 Lift Eyes (2)., 303-1246 Engine Spreader Bar.
    2. Support the engine using the floor crane and length of chain with connecting links. Use the General Equipment: Floor Crane

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79. Remove. Use the General Equipment: Adjustable Mounting Arm

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80. NOTE: 4WD shown, 2WD similar.

    Remove the transmission bellhousing bolts.

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81. NOTE: 4WD shown, 2WD similar.

    If equipped, remove the transmission bellhousing bolt.

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82. 1. Remove the bellhousing bolts.
    2. Separate the engine from the transmission.

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83. Remove the engine from the transmission and subframe assembly. Use the General Equipment: Floor Crane

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84. Install Special Service Tool: 307-346 (T97T-7902-A) Retainer, Torque Converter.

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