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Transaxle - Front Wheel Drive (FWD): Removal

WARNING: This page is about a different car, the 2005 Mercury Montego, 2005 Ford Freestyle, and 2005 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Remove the battery and battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  3. Remove the air cleaner and the outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  4. Remove the cowl panel grille. For additional information, refer to FRONT END BODY PANELS .
  5. Remove the upper roll restrictor bolt.
    Fig 1: Identifying Upper Roll Restrictor
    G03989188Courtesy of FORD MOTOR CO.
  6. Remove the 4 roll restrictor brace bolts and the roll restrictor brace.
    Fig 2: Identifying Transaxle Roll Restrictor Bar Bolts
    G03989189Courtesy of FORD MOTOR CO.
  7. Disconnect the shift cable end.
    Fig 3: Disconnecting Shift Cable End
    G03990221Courtesy of FORD MOTOR CO.
  8. Remove the electrical connector from the shift cable bracket.
    Fig 4: Locating Electrical Connector At Shift Cable Bracket
    G03990909Courtesy of FORD MOTOR CO.
  9. Remove the 2 bolts for the shift cable bracket and position the cable and bracket aside.
    Fig 5: Removing 2 Bolts For Shift Cable Bracket
    G03990223Courtesy of FORD MOTOR CO.
  10. Disconnect the wire harness from the transaxle.
    Fig 6: Locating Wire Harness At Transaxle
    G03990911Courtesy of FORD MOTOR CO.
  11. If equipped, remove the auxiliary coolant flow pump assembly.
    1. Disconnect the electrical connector.
    2. Remove the bolts and position the pump assembly aside.
      Fig 7: Removing Bolts And Positioning Pump Assembly Aside
      G03990912Courtesy of FORD MOTOR CO.
  12. Disconnect the lower wire harness from the transaxle.
    Fig 8: Disconnecting Lower Wire Harness From Transaxle
    G03990913Courtesy of FORD MOTOR CO.
  13. Remove the 4 bolts and the roll restrictor bracket.
    Fig 9: Removing Bolts And Roll Restrictor Bracket
    G03990914Courtesy of FORD MOTOR CO.
  14. Disconnect the wire harness from the roll restrictor, remove the 2 bolts and remove the roll restrictor.
    Fig 10: Locating Wire Harness At Roll Restrictor
    G03990915Courtesy of FORD MOTOR CO.
  15. Remove the positive crankcase ventilation (PCV) hose.
    Fig 11: Removing Positive Crankcase Ventilation (PCV) Hose
    G03990916Courtesy of FORD MOTOR CO.
  16. Disconnect the vacuum hoses from the throttle body.
    Fig 12: Disconnecting Vacuum Hoses From Throttle Body
    G03990917Courtesy of FORD MOTOR CO.
  17. Remove the bolt for the power steering line bracket and position aside.
    Fig 13: Removing Bolt For Power Steering Line Bracket
    G03990996Courtesy of FORD MOTOR CO.
  18. Remove the plastic electrical cover for the starter motor electrical connectors.
    Fig 14: Identifying Electrical Cover For Starter Motor Electrical Connectors
    G03990919Courtesy of FORD MOTOR CO.
  19. Disconnect the 2 starter motor electrical connectors.
    Fig 15: Identifying Starter Motor Electrical Connectors
    G03990920Courtesy of FORD MOTOR CO.
  20. Remove the 2 bolts for the starter and remove the starter.
    Fig 16: Identifying Starter Motor Mounting Bolts
    G03990263Courtesy of FORD MOTOR CO.
  21. Remove the fluid cooler tube bracket from the transaxle.
    Fig 17: Identifying Fluid Cooler Tube Bracket/Bolt To Transaxle
    G03991000Courtesy of FORD MOTOR CO.
  22. Disconnect the ground wire.
    Fig 18: Disconnecting Ground Wire
    G03991001Courtesy of FORD MOTOR CO.
    23. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
  23. Disconnect the transaxle bulk head electrical connector.
    • Rotate the electrical connector counterclockwise to disconnect.
      Fig 19: Identifying Transaxle Bulkhead Electrical Connector
      G03990860Courtesy of FORD MOTOR CO.
  24. Disconnect the wire harness from the transaxle.
    Fig 20: Disconnecting Wire Harness From Transaxle
    G03991003Courtesy of FORD MOTOR CO.
  25. Remove the 4 upper transaxle bolts.
    Fig 21: Removing Upper Transaxle Bolts
    G03990288Courtesy of FORD MOTOR CO.
  26. If a transaxle exchange or overhaul is required, the transmission fluid must be drained.
    • Remove the drain plug and allow the fluid to drain.
      Fig 22: Locating Fluid Pan Drain Plug
      G03990683Courtesy of FORD MOTOR CO.
  27. Remove the LH and RH halfshafts. For additional information, refer to FRONT DRIVE HALFSHAFTS .
  28. If removed, install the drain plug.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 23: Locating Fluid Pan Drain Plug
      G03990683Courtesy of FORD MOTOR CO.
  29. Remove and discard the 2 nuts for the front exhaust pipe.
    Fig 24: Identifying Exhaust Pipe Nuts
    G03990730Courtesy of FORD MOTOR CO.
  30. Remove and discard the 2 nuts for the rear exhaust pipe.
    Fig 25: Identifying Nuts For Rear Exhaust Pipe
    G03990731Courtesy of FORD MOTOR CO.
  31. Remove and discard the 2 nuts for the catalytic converter pipe, disconnect the rubber hanger and remove the pipe.
    Fig 26: Identifying Nuts For Catalytic Converter Pipe
    G03990732Courtesy of FORD MOTOR CO.
  32. If equipped, disconnect the engine block heater electrical connector.
    Fig 27: Locating Engine Block Heater
    G03990550Courtesy of FORD MOTOR CO.
  33. Position the heat shield for the knock sensor aside.
    Fig 28: Identifying Heat Shield Over Knock Sensor
    G03990937Courtesy of FORD MOTOR CO.
  34. Remove the bolt and remove the knock sensor.
    Fig 29: Locating Knock Sensor
    G03990667Courtesy of FORD MOTOR CO.
  35. Disconnect the knock sensor wire harness from the transaxle.
    Fig 30: Disconnecting Knock Sensor Wire Harness From Transaxle
    G03991013Courtesy of FORD MOTOR CO.
  36. Remove the transaxle-to-engine bolt.
    Fig 31: Removing Transaxle-To-Engine Bolt
    G03990940Courtesy of FORD MOTOR CO.
  37. Remove the bolt for the power steering hose.
    Fig 32: Removing Bolt For Power Steering Hose
    G03990941Courtesy of FORD MOTOR CO.
    38. NOTE: When installing the lifting bracket it will be easier to loosely install the upper bolt first then install the lower bolt.
    Fig 33: Identifying Lower Half Of Lifting Hook
    G03990010Courtesy of FORD MOTOR CO.
  38. Install the lower half of the lifting hook.
  39. Install the upper half of the lifting hook.
    Fig 34: Identifying Upper Half Of Lifting Hook
    G03990011Courtesy of FORD MOTOR CO.
  40. Disconnect the vapor tube from the canister purge valve.
    Fig 35: Disconnecting Vapor Tube From Canister Purge Valve
    G03990216Courtesy of FORD MOTOR CO.
  41. Remove the bolt for the power steering hose.
    Fig 36: Removing Bolt For Power Steering Hose
    G03990945Courtesy of FORD MOTOR CO.
  42. Install the special tool to the RH cylinder head.
    Fig 37: Installing Special Tool To RH Cylinder Head
    G03990013Courtesy of FORD MOTOR CO.
  43. Remove and discard the 2 bolts for the catalytic converter.
    Fig 38: Locating Bolts For Catalytic Converter
    G03990947Courtesy of FORD MOTOR CO.
  44. Install the special tool to the LH cylinder head.
    Fig 39: Installing Special Tool To LH Cylinder Head
    G03990012Courtesy of FORD MOTOR CO.
  45. Install the special tools to support the engine assembly.
    Fig 40: Identifying Special Tools To Support Engine Assembly
    G03990949Courtesy of FORD MOTOR CO.
  46. Install the special tools to the LH (front) cylinder head.
    Fig 41: Installing Special Tools To LH (Front) Cylinder Head
    G03990950Courtesy of FORD MOTOR CO.
  47. Install the special tools to the RH (rear) cylinder head.
    Fig 42: Installing Special Tools To RH (Rear) Cylinder Head
    G03990016Courtesy of FORD MOTOR CO.
  48. Install the special tools into the lifting hook near the EGR valve.
    Fig 43: Identifying Special Tools In Lifting Hook Near EGR Valve
    G03990017Courtesy of FORD MOTOR CO.
  49. Disconnect the lower radiator hose from the retainers and position the hose aside.
    Fig 44: Disconnecting Lower Radiator Hose
    G03990953Courtesy of FORD MOTOR CO.
  50. Remove the 4 bolts that hold the power steering line to the subframe.
    Fig 45: Removing Bolts That Hold Power Steering Line To Subframe
    G03990954Courtesy of FORD MOTOR CO.
  51. Disconnect the wire harness from the LH front of the subframe.
    Fig 46: Disconnecting Wire Harness From LH Front Of Subframe
    G03991029Courtesy of FORD MOTOR CO.
  52. Remove the bolts and nuts for the power steering rack. Use mechanic's wire to hold the power steering rack up to the side.
    Fig 47: Removing Bolts And Nuts For Power Steering Rack
    G03990956Courtesy of FORD MOTOR CO.
  53. Disconnect the HO2S electrical connector from the subframe.
    Fig 48: Disconnecting HO2S Electrical Connector From Subframe
    G03990957Courtesy of FORD MOTOR CO.
  54. Disconnect the 3 push pins and position the splash shield aside.
    Fig 49: Disconnecting Push Pins
    G03990958Courtesy of FORD MOTOR CO.
  55. Remove the nut for the front motor mount.
    Fig 50: Removing Nut For Front Motor Mount
    G03990959Courtesy of FORD MOTOR CO.
  56. Remove the 2 bolts for the lower stabilizer mount.
    Fig 51: Removing Bolts For Lower Stabilizer Mount
    G03990960Courtesy of FORD MOTOR CO.
  57. Remove the nut for the rear motor mount.
    Fig 52: Removing Nut For Rear Motor Mount
    G03990961Courtesy of FORD MOTOR CO.
  58. Remove the bolts for the rear transaxle mount.
    Fig 53: Identifying Bolts For Rear Transaxle Mount
    G03990748Courtesy of FORD MOTOR CO.
  59. Remove the 2 bolts for the LH rear subframe mount.
    Fig 54: Removing Bolts For LH Rear Subframe Mount
    G03990963Courtesy of FORD MOTOR CO.
  60. Remove the 2 bolts for the RH rear subframe mount.
    Fig 55: Removing Bolts For RH Rear Subframe Mount
    G03990964Courtesy of FORD MOTOR CO.
  61. Remove and discard the LH and RH stabilizer bar link nuts and separate the stabilizer bar links from the struts.
    Fig 56: Identifying Stabilizer Bar Link Nuts
    G03990245Courtesy of FORD MOTOR CO.
  62. Using a suitable powertrain lift, remove the 4 subframe bolts and remove the subframe.
    Fig 57: Removing Subframe Bolts And Subframe
    G03990966Courtesy of FORD MOTOR CO.
  63. Disconnect the HO2S electrical connector.
    Fig 58: Disconnecting HO2S Electrical Connector
    G03990967Courtesy of FORD MOTOR CO.
  64. Remove the bolt for the catalytic converter bracket and remove the catalytic converter.
    Fig 59: Locating Bolt At Catalytic Converter Bracket
    G03991042Courtesy of FORD MOTOR CO.
  65. Remove the 2 push pins and remove the rubber access plug.
    Fig 60: Locating Rubber Access Plug
    G03990969Courtesy of FORD MOTOR CO.
  66. Remove and discard the 4 torque converter nuts.
    Fig 61: Identifying Torque Converter Nuts
    G03990970Courtesy of FORD MOTOR CO.
    67. CAUTION: When disconnecting the fluid cooler tubes pull straight up to prevent damage to the fluid cooler tubes.
    Fig 62: Identifying Transmission Fluid Cooler Tubes To Transaxle Bolt
    G03990696Courtesy of FORD MOTOR CO.
  67. Disconnect the transmission fluid cooler tubes from the transaxle.
  68. Remove and discard the 4 transmission fluid cooler tube seals.
    Fig 63: Locating O-Ring Seals
    G03990854Courtesy of FORD MOTOR CO.
  69. Remove the transmission fluid cooler tube bracket bolts.
    Fig 64: Removing Transmission Fluid Cooler Tube Bracket Bolts
    G03990973Courtesy of FORD MOTOR CO.
    70. NOTE: Make sure that the transaxle is securely fastened to the transmission jack.
  70. Position a suitable high-lift transmission jack under the transaxle.
  71. Remove the 3 transaxle-to-engine bolts.
    Fig 65: Locating Transaxle-To-Engine Bolts
    G03990545Courtesy of FORD MOTOR CO.
  72. Remove the transaxle from under the vehicle.
  73. If the transaxle is to be overhauled or if installing a new transaxle, install a new transmission fluid cooler. For additional information, refer to TRANSAXLE/TRANSMISSION COOLING .
  74. If the transaxle is to be overhauled or if installing a new transaxle, carry out transmission backflushing and cleaning. For additional information, refer to TRANSMISSION FLUID COOLER TUBES - BACKFLUSHING AND CLEANING .
  75. If removing the transaxle for something other than a transaxle related repair, inspect the differential seals for damage or leaking. If leaking or damage is indicated install new differential seals. For additional information, refer to DIFFERENTIAL SEALS - LH , DIFFERENTIAL SEALS - RH, ALL WHEEL DRIVE (AWD)  or DIFFERENTIAL SEALS - RH, FRONT WHEEL DRIVE (FWD) .
  76. If installing a new transaxle, remove the bolts and remove the rear transaxle support insulator.
    Fig 66: Removing Bolts And Rear Transaxle Support Insulator
    G03991049Courtesy of FORD MOTOR CO.
  77. If installing a new transaxle, remove and discard the 4 retainers and remove the transaxle insulator.
    Fig 67: Removing Retainers And Transaxle Insulator
    G03990976Courtesy of FORD MOTOR CO.
  78. If installing a new transaxle, remove the bolt and remove the fluid level indicator and tube.
    Fig 68: Removing Bolt And Fluid Level Indicator And Tube
    G03990977Courtesy of FORD MOTOR CO.
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