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In-vehicle Repair|Disassembly > < Engine - Vehicles With: MMT6-6-Speed Manual Transaxle

Mondeo 2001 (10.2000-02.2007)

Engine - 2.5L Duratec-VE (VE6) - Engine—Vehicles With: 5F31J/5-Speed Automatic Transmission Mondeo 2001 (10/2000-02/2007)
Removal

Special Tool(s)

Remover/Installer, Hose Clamp

303-397 (24-003)

Remover, Transmission Fluid Cooler

307-242 (17-049)

Remover, Halfshaft

308-256 (16-089)
General Equipment
Workshop table
Workshop hoist
Securing straps

Removal

All vehicles
WARNING:
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 ignite. Failure to follow these instructions may result in personal injury.
  1. Disconnect the battery ground cable. For additional information, refer to Section  414-01 Battery, Mounting and Cables.

  1. Remove the strut and spring assembly top mount brace cover on both sides (left-hand side shown).

  1. Loosen the strut and spring assembly top mount nuts by four turns on both sides.

  1. Remove the air cleaner.
    1. Disconnect the positive crankcase ventilation (PCV) hoses.
    1. Disconnect the mass air flow (MAF) sensor electrical connector.
    1. Detach the air cleaner outlet hose.

  1. Remove the engine cover.

  1. Detach the brake booster vacuum pipe from the intake manifold.

  1. Disconnect the fuel supply line. For additional information, refer to Section  310-00 Fuel System - General Information.
  1. Drain the cooling system. For additional information, refer to Section  303-03 Engine Cooling.
  1. Remove the accessory drive belt. For additional information, refer to Section  303-05 Accessory Drive.
  1. Remove the subframe. For additional information, refer to Section  502-00 Uni-Body, Subframe and Mounting System.
  1. Lower the vehicle.

  1. Detach the accelerator cable.
    • Detach the clips and the accelerator cable from the bracket.

  1. Using the special tool, disconnect the coolant hoses from the coolant connecting pipe.

  1. Detach evaporative emission (EVAP) solenoid valve from the intake manifold.

  1. Disconnect the electronic ignition (EI) coil electrical connectors.

  1. Remove the EI coil.

  1. Disconnect the heated oxygen sensor (HO2S) electrical connector.

  1. Detach the engine wiring harness from the right-hand valve cover.

  1. Disconnect the engine wiring harness electrical connectors.

  1. Disconnect the ground cable from the transaxle.

  1. Disconnect the starter motor electrical connectors.

  1. Detach the power steering pump line support bracket from the engine front mount.

  1. Disconnect the power steering line.
    • Remove the clip.
    • Allow the fluid to drain into a suitable container.

  1. Using the special tool, disconnect the power steering pump hose from the power steering pump.
    • Allow the fluid to drain into a suitable container.

  1. Detach the power steering fluid reservoir from the radiator grille opening panel and position it to one side.

  1. Disconnect the vent hose from the transaxle.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. CAUTION:
    CAUTION:Support the halfshaft. The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
    NOTE:
    NOTE:Do not damage the halfshaft seal.
    NOTE:
    NOTE:Cap the transaxle to prevent oil loss and dirt ingress.
    Using the special tool, detach the left-hand halfshaft from the transaxle and secure it to one side.
    • Discard the snap ring.
    • Discard the O-ring seal.

  1. CAUTION:
    CAUTION:Support the halfshaft. The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
    NOTE:
    NOTE:Do not damage the halfshaft seal.
    NOTE:
    NOTE:Cap the transaxle to prevent oil loss and dirt ingress.
    Detach the right-hand halfshaft and the intermediate shaft from the transaxle and secure it to one side.
    • Discard the O-ring seal

  1. Using the special tool, disconnect the lower coolant hose from the radiator.

  1. Disconnect the air conditioning (A/C) electrical connector.

  1. CAUTION:
    CAUTION:Support the A/C compressor before removing the retaining bolts and secure it to prevent load being placed on the refrigerant lines.
    Detach the A/C compressor from the mounting bracket and secure it to one side.
Vehicles built up to 03/2003
  1. NOTE:
    NOTE:Cap the fluid cooler pipes to prevent oil loss and dirt ingress.
    Disconnect the fluid cooler pipes from the transaxle.
    • Allow the fluid to drain into a suitable container.
Vehicles built 03/2003 onwards
  1. NOTE:
    NOTE:Cap the fluid cooler openings to prevent oil loss and dirt ingress.
    Using the special tool, disconnect the fluid cooler pipes.
    1. Insert the special tool into the quick-release coupling.
    1. Slide the special tool along the pipe to release the locking tangs.
    • Allow the fluid to drain into a suitable container.
All vehicles
  1. Disconnect the transaxle electrical connectors.

  1. Remove the selector cable cover.

  1. NOTE:
    NOTE:Make sure the transaxle selector lever is in "P" (PARK) position.
    Detach the selector lever cable from the transaxle.
    1. Detach the selector lever cable from the selector shaft.
    1. Detach the selector lever cable from the transaxle.

  1. Remove the torque converter retaining nuts.
    • Remove the cover.
    • Rotate the engine to gain access to the nuts.
    • Discard the nuts.
  1. Position the workshop table under the vehicle and carefully lower the vehicle, until the engine and transaxle assembly is in the correct position to remove the engine mounts.

  1. CAUTION:
    CAUTION:Do not support directly on the oil pan.
    NOTE:
    NOTE:Using suitable securing straps, secure the engine and the transaxle on a workshop table.
    Using suitable wooden blocks, support the engine and transaxle assembly.

  1. Detach the spark plug cable retaining bracket from the engine front mount.

  1. Remove the engine front mount bracket retaining nuts.
    • Discard the nuts.

  1. Remove the engine rear mount.
    • Discard the nuts.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Remove the starter motor.

  1. Remove the transaxle lower retaining bolts.

  1. Remove the transaxle right-hand retaining bolts.

  1. Remove the transaxle left-hand retaining bolts.

  1. Remove the transaxle upper retaining bolts.
  1. Remove the transaxle from the engine.

In-vehicle Repair|Disassembly > < Engine - Vehicles With: MMT6-6-Speed Manual Transaxle