Ford Workshop Service and Repair Manuals

Engine Support Leg

303-290A-03A

Exhaust Holder Tool

309-001 (T94T-6000-AH) (25-001)

3 Bar Engine Support Bar

303-290A

Cat Walk Adapters

303-290A-01

Engine Lifting Chains (Part of Spreader Bar)

303-D089 (D93P-6001-A3) or equivalent

Torque Converter Holding Tool

307-346 (T97T-7902-A)

1. Disconnect the battery cables. For additional information, refer to Section 414-01 Battery, Mounting and Cables.

2. Remove the battery and the battery tray. For additional information, refer to Section 414-01 Battery, Mounting and Cables.

3. Disconnect the breather tube and mass air flow (MAF) sensor.

4. Remove the intake tube and air cleaner cover.

5. Remove the air cleaner assembly.

6. Disconnect the transmission range (TR) sensor.

7. Disconnect the HO2S sensor.

8. Disconnect the transaxle harness connector and remove the wire harness bracket nut.

9. Position the wire harness bracket out of the way.

10. Disconnect the vent hose from transmission filler tube bracket.

11. Unclip the wire harness.

12. Disconnect the shift cable.

13. Disconnect the wire harness from the shift cable bracket to gain access to the bracket bolts.

14. Remove the shift cable and bracket, and position out of the way.

15. Disconnect the starter motor harness connector.

16. Disconnect the ground wire.

17. Remove two starter bolts, and remove the starter motor.

18. Install the special tools.

19. Remove both electrical connectors from the upper intake to gain access to the engine lifting bracket.

20. Install the special tools.

21. Install the special tools.

22. Remove the upper transaxle retaining bolts.

23. Remove the LH upper transaxle mount plate.

24. Remove the bolts, and remove the rear transaxle mount.

25. Remove the RH engine mount bolt.

26. 

    NOTE:It is necessary to raise the engine a couple of inches in order to remove the transaxle.
    Using the special tool raise the engine.

27. Raise and support the vehicle. For additional information, refer to Section 100-02 Jacking and Lifting.

28. Remove both front wheels. For additional information, refer to Section 204-04 Wheels and Tires.

29. Remove the two splash shields.

30. Disconnect the two HO2S sensors.

31. If transaxle disassembly is necessary, remove the drain plug and drain the fluid into a suitable container.
    • Install the drain plug when the fluid has drained.

32. 

    CAUTION:Index-mark the mounting bracket studs and the intermediate shaft bearing bracket holes for correct assembly.
    Remove the RH halfshaft, intermediate shaft bearing, and intermediate shaft assembly. For additional information, refer to Section 205-04 Front Drive Halfshafts.

33. Remove the LH halfshaft assembly. For additional information, refer to Section 205-04 Front Drive Halfshafts.

34. Remove the cross brace.

35. Disconnect the HO2S sensor connector and unclip the two clips from the oil pan bolt studs.

36. Remove the exhaust pipe.
    1. Install the special tool.
    2. Remove the rubber hanger.
    3. Remove the bolts, and remove the pipe.

37. Disconnect the front exhaust pipe flange.

38. Disconnect the rear exhaust pipe flange and remove the exhaust pipe.

39. If equipped, remove the rear driveshaft. For additional information, refer to Section 205-01 Driveshaft.

40. For four-wheel-drive vehicles, remove the RH exhaust manifold to gain access to the PTU bracket. For additional information, refer to Section 303-01A EngineSection 303-01B Engine.

41. Remove the bolts and the bracket.

42. Remove the cross brace dampner.

43. Remove the cross brace.

44. Remove the bolts from the PTU unit.

45. Remove the PTU bolt and remove the PTU unit.

46. Lower the vehicle.

47. 

    NOTE:It is necessary to lower the transaxle in order to clear the subframe to remove the transaxle.
    Lower the transaxle enough to clear the subframe.

48. Raise and support the vehicle. For additional information, refer to Section 100-02 Jacking and Lifting.

49. Remove the access cover.

50. Remove the four flexplate nuts.

51. Remove the fluid cooler tube.
    1. Disconnect the output shaft speed (OSS) sensor.
    2. Disconnect the turbine shaft speed (TSS) sensor.
    3. Remove the bolt.
    4. Remove the fluid cooler tube and position it aside.

52. Remove the OSS sensor.

53. Remove the fluid cooler line.

54. Install the transmission jack and secure the transaxle to the jack.

55. Remove the bolts.

56. Remove the vent tube.

57. Remove the bolt.

58. Remove the bolt.

59. 

    CAUTION:The torque converter is heavy. Install the special tool before lowering the transaxle.
    Move the transaxle back far enough to install the special tool.

60. Lower the transaxle from the engine compartment with the PTU unit attached.