Removal (Aerostar)

Disconnect negative and positive battery cable. Remove battery cable support bracket and secure cables to engine. Drain cooling system. Disconnect PCV hose from air cleaner duct. Remove air cleaner and intake duct assembly. Mark and remove vacuum hoses from power brake booster, cruise control (if equipped), MAP sensor and A/C check valve. Secure vacuum hoses to engine. Remove radiator hoses.
Disconnect power steering pressure switch. Remove power steering pressure hose from fan shroud. Rest fan shroud on radiator. Disconnect transmission cooler lines from radiator. Remove 2 upper radiator retaining bolts and remove radiator and fan shroud.
Disconnect fuel injector harness connector from main Powertrain Control Module (PCM) harness. Disconnect and remove heater hoses. Loosen pinch bolt and separate steering column from intermediate shaft. Discharge A/C system using approved refrigerant recovery/recycling equipment. Disconnect A/C liquid line at condenser and suction line from accumulator. Disconnect canister purge solenoid hoses from solenoid and secure to engine. Release fuel pressure. See FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS . Remove oil dipstick. Raise and support vehicle.
NOTE: Place a wooden block between rear engine cradle and front oil pan surface to prevent engine from tilting rearward while removing transmission. Failure to support engine may damage engine components.
Remove front wheels. Drain transmission. Remove transmission housing cover from converter housing. Remove housing cover bolt, and pivot cover open. Remove starter motor and position aside. Remove 4 flywheel attaching nuts. Scribe a mark indexing drive shaft to rear axle flange.
Remove drive shaft and install Extension Housing Seal Replacer (T74P-77052-A) into extension housing. Disconnect transmission shift bellcrank from ball stud lever. Depress tab on downshift cable retainer and remove cable from bracket.
Disconnect park/neutral position switch, torque converter clutch and 3/4 shift solenoid connector. Remove vacuum hose from vacuum throttle valve diaphragm. Place transmission jack under transmission. Raise transmission slightly. Remove rear engine mount-to-crossmember bolts. Remove mount (if necessary). Remove crossmember-to-frame volts. Remove crossmember.
Disconnect exhaust inlet pipe and any other components for clearance. Lower transmission jack and allow transmission to hang. Disconnect and plug cooler lines from transmission. Remove lower bellhousing-to-engine bolts. Remove fluid filler tube from short inlet safety chain. Remove 2 upper bellhousing-to-engine bolts. Slide transmission rearward.
Lower transmission from vehicle. Loosen and remove exhaust manifold stud nuts. Disconnect and remove muffler and catalytic converter. Remove dash panel ground cables from cylinder head behind power steering pump and above where exhaust manifold and catalytic converter connect. Remove stabilizer bar nuts and discard. Disconnect stabilizer bar from lower control arms.
Remove brake calipers and position aside. Using Spring Lock Coupling Remover (T81P-19623-G1 for 3/8" line or T81P-19623-G2 for 1/2" line), disconnect fuel supply and return lines along left frame rail. See Figure. Place jack under lower control arm and raise jack until tension is applied to coil spring. Remove upper spindle-to-control arm ball joint pinch bolt. Slowly lower jack to disconnect spindle from ball joint.
Position Drive Train Removal Lift (014-00265) under crossmember and engine assembly. Lower vehicle until crossmember rests on lift. Place wood blocks under front crossmember and rear of engine to keep unit level.
Install safety chains around crossmember and lift. With engine and crossmember securely supported on lift, remove 3 engine and crossmember-to-frame retaining bolts from each side of vehicle.
Slowly lower engine assembly from vehicle. Ensure A/C compressor and wiring harnesses do not interfere with removal process. Raise body from engine and crossmember assembly. Remove motor mount nuts. Remove engine from crossmember.