Engine - Automatic Transaxle

Illustration	Tool Name	Tool Number
Courtesy of FORD MOTOR CO.	Front Drive Halfshaft Remover	205-241 (T86P-3514-A)
Courtesy of FORD MOTOR CO.	Heavy Duty Floor Crane	014-00071 or equivalent
Courtesy of FORD MOTOR CO.	Powertrain Lift	014-00765
Courtesy of FORD MOTOR CO.	Slide Hammer	100-001 (T50T-100-A)
Courtesy of FORD MOTOR CO.	Spreader Bar	303-D089 (D93P-6001-A3) or equivalent
Courtesy of FORD MOTOR CO.	Tie-Rod End Remover	211-105 (T85M-3395-A)
Courtesy of FORD MOTOR CO.	Universal Adapter Brackets	014-0001

All vehicles 

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING article.
2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
3. Remove the engine air cleaner and air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - 2.3L article.
4. Remove the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
5. Drain the engine oil.
   • Install the drain plug.
   • Tighten to 28 Nm (21 lb-ft).
6. Remove the front wheels and tires. For additional information, refer to WHEELS AND TIRES article.
7. Drain the cooling system. For additional information, refer to ENGINE COOLING article.
8. Remove the exhaust flexible pipe. For additional information, refer to EXHAUST SYSTEM article.
9. Disconnect the heated oxygen sensor (HO2S) and the catalyst monitor sensor electrical connectors.
Fig 1: Heated Oxygen Sensor (HO2S) And Catalyst Monitor Sensor Electrical Connectors
Courtesy of FORD MOTOR CO.
10. Remove the accessory drive belt and tensioner. For additional information, refer to ACCESSORY DRIVE - 2.3L article.
11. Press the 2 locking tabs (1 shown) to release the lower air duct from the upper air duct.
Fig 2: Identifying Locking Tab
Courtesy of FORD MOTOR CO.
12. Detach the wire retainers from the generator shield and remove the nut and pin-type retainer.
    • Remove the generator shield.
Fig 3: Generator Shield
Courtesy of FORD MOTOR CO.
13. Remove the bolts and the lateral support crossmember.
Fig 4: Identifying Lateral Support Crossmember And Bolts
Courtesy of FORD MOTOR CO.
14. Remove the brake hose retainer and the ABS sensor retaining bolt from the LH strut.
Fig 5: Identifying Bolt
Courtesy of FORD MOTOR CO.
15. Disconnect the LH suspension.
    1. Disconnect the stabilizer bar link.
    2. Remove the tie rod end retaining nut.
    3. Remove the lower control arm knuckle bolt.
Fig 6: Identifying Stabilizer Bar Link, Retaining Nut, And Knuckle Bolt
Courtesy of FORD MOTOR CO.
16. Remove the brake hose retainer and the ABS sensor retaining bolt from the RH strut.
Fig 7: Identifying Bolt
Courtesy of FORD MOTOR CO.
17. Disconnect the RH suspension.
    1. Disconnect the stabilizer bar link.
    2. Remove the tie rod end retaining nut.
    3. Remove the lower control arm knuckle bolt.
Fig 8: Identifying Stabilizer Bar Link, Retaining Nut, And Knuckle Bolt
Courtesy of FORD MOTOR CO.
18. Using the special tool, disconnect the LH and RH tie rod end from the steering knuckle.
Fig 9: Disconnecting LH And RH Tie Rod End From Steering Knuckle
Courtesy of FORD MOTOR CO.
19. Separate the LH and RH lower control arms from the lower ball joints and position the steering knuckles aside.
20. Using a suitable tool, separate the LH halfshaft from the transaxle and secure the halfshaft aside.
21. Using the special tools, remove the RH halfshaft from the intermediate shaft and secure the halfshaft aside.
Fig 10: Removing RH Outer Halfshaft Using Special Tools
Courtesy of FORD MOTOR CO.
22. Remove the 2 intermediate shaft retaining nuts.
Fig 11: Locating Intermediate Shaft Retaining Nuts
Courtesy of FORD MOTOR CO.
23. Remove the intermediate shaft.
Fig 12: Locating Intermediate Shaft
Courtesy of FORD MOTOR CO.

All wheel drive (AWD) vehicles 

NOTE: Index-mark the driveshaft to the yoke for installation.
24. Remove the 6 bolts holding the driveshaft to the PTU and position aside with mechanic's wire.
Fig 13: Locating Driveshaft & Bolts
Courtesy of FORD MOTOR CO.

All vehicles 

25. If equipped, remove the bolt and ground eyelet.
Fig 14: Ground Eyelet & Bolt
Courtesy of FORD MOTOR CO.
26. Remove the power distribution box (PDB) cover.
Fig 15: Locating Power Distribution Box Cover
Courtesy of FORD MOTOR CO.
27. Remove the nut and disconnect the cable from the PDB.
Fig 16: Identifying Nut
Courtesy of FORD MOTOR CO.
28. Disconnect the electrical connector from the PDB.
Fig 17: Power Distribution Box Electrical Connector
Courtesy of FORD MOTOR CO.
29. Remove the bolt and the ground strap.
Fig 18: Identifying Bolt
Courtesy of FORD MOTOR CO.
30. Disconnect the 34-pin electrical connector.
Fig 19: Identifying Connector
Courtesy of FORD MOTOR CO.
31. Detach the wiring harness retainers from the battery tray bracket.
Fig 20: Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
32. Detach the transaxle vent tube retaining clip from the engine wiring harness.
Fig 21: Identifying Retaining Clip
Courtesy of FORD MOTOR CO.
33. Remove the nut holding the wiring harness bracket and unplug the transaxle electrical connector.
Fig 22: Identifying Nut And Connector
Courtesy of FORD MOTOR CO.
34. Disconnect the shift cable from the transaxle manual lever.
Fig 23: Locating Shift Cable End At Manual Lever
Courtesy of FORD MOTOR CO.
35. Detach the wiring harness pin-type retainer and remove the 2 bolts.
    • Position the transaxle cable and bracket aside.
Fig 24: Transaxle Control Cable & Bracket
Courtesy of FORD MOTOR CO.
36. Disconnect the transaxle range sensor electrical connector.
Fig 25: Locating Transmission Range (TR) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
37. Disconnect the front transaxle fluid cooler tube.
Fig 26: Locating Transmission Fluid Cooler Tube
Courtesy of FORD MOTOR CO.
38. Disconnect the rear transaxle fluid cooler tube.
Fig 27: Rear Cooler Tube At Transaxle Case
Courtesy of FORD MOTOR CO.
39. Disconnect the transaxle fluid cooler tube.
    1. Disconnect the output shaft speed (OSS) sensor electrical connector (black).
    2. Disconnect the turbine shaft speed (TSS) sensor electrical connector (white).
       • Disconnect the wiring harness retainer from the transaxle case and position the harness aside.
    3. Remove the transaxle fluid cooler retaining bracket bolt.
    4. Position the fluid cooler tube aside.
Fig 28: Fluid Cooler Tube, Electrical Connectors & Bracket
Courtesy of FORD MOTOR CO.
40. Remove the bolt and the OSS sensor.
Fig 29: Locating OSS Sensor Bolt
Courtesy of FORD MOTOR CO.
41. If equipped, disconnect the block heater electrical connector.
    • Detach all the block heater wiring harness retainers and position the wiring harness aside.
Fig 30: Block Heater Electrical Connector
Courtesy of FORD MOTOR CO.
42. Disconnect the upper radiator hose.
Fig 31: Identifying Upper Radiator Hose
Courtesy of FORD MOTOR CO.
43. Detach the heater hose support strap from the stud.
Fig 32: Heater Hose Support Strap & Stud
Courtesy of FORD MOTOR CO.
44. Disconnect the heater hoses from the heater core.
Fig 33: Locating Heater Hoses
Courtesy of FORD MOTOR CO.
45. Remove the retainers and the accelerator cable snow shield.
Fig 34: Accelerator Cable Snow Shield Retainers
Courtesy of FORD MOTOR CO.
46. Disconnect the accelerator cable and speed control cable (if equipped).
    1. Disconnect the accelerator and speed control cable (if equipped) from the throttle body.
    2. Remove the bolts from the accelerator cable bracket.
Fig 35: Accelerator Cable, Speed Control Cable & Bracket Bolts
Courtesy of FORD MOTOR CO.
47. Remove the nut from the accelerator control cable bracket.
Fig 36: Accelerator Control Cable Bracket & Nut
Courtesy of FORD MOTOR CO.
48. Remove the nut from the accelerator control cable bracket.
    • Position the accelerator control cable and bracket assembly aside.
Fig 37: Accelerator Control Cable Bracket & Nut
Courtesy of FORD MOTOR CO.
49. Disconnect the vacuum supply tube and position aside.
Fig 38: Vacuum Supply Tube
Courtesy of FORD MOTOR CO.
50. Disconnect the fuel vapor return tube and retainer and position aside.
Fig 39: Fuel Vapor Return Tube
Courtesy of FORD MOTOR CO.
51. Disconnect the fuel supply tube quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
Fig 40: Identifying Fuel Supply Tube Quick Connect Coupling
Courtesy of FORD MOTOR CO.
52. Detach the electrical connector retainers.
Fig 41: Electrical Connector Retainers
Courtesy of FORD MOTOR CO.
53. Remove the bolt and detach the ground wire.
Fig 42: Locating Ground Wire & Bolt
Courtesy of FORD MOTOR CO.
54. Disconnect the PCM electrical connectors.
    • Remove the wiring harness retainer nut.
Fig 43: Identifying Connectors
Courtesy of FORD MOTOR CO.
55. Disconnect the lower radiator hose from the radiator.
Fig 44: Locating Lower Radiator Hose
Courtesy of FORD MOTOR CO.
56. Disconnect the A/C compressor electrical connector and remove the 4 bolts.
    • Position the A/C compressor aside and support the compressor with a length of mechanic's wire.
Fig 45: A/C Compressor Electrical Connector & Bolts
Courtesy of FORD MOTOR CO.
57. Remove the front roll restrictor bolt and the 2 bolts for the engine support crossmember.
Fig 46: Identifying Front Roll Restrictor Bolt & Bolts For Engine Support Crossmember
Courtesy of FORD MOTOR CO.
58. Remove the rear nut and the engine support crossmember.
    • Discard the nut.
Fig 47: Identifying Cross Brace And Rear Nut
Courtesy of FORD MOTOR CO.

Front wheel drive (FWD) vehicles 

59. Remove the 3 bolts and the damper.
Fig 48: Locating Bolts & Dampener
Courtesy of FORD MOTOR CO.

All vehicles 

NOTE: The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.
60. Remove the 2 transaxle-to-engine bolts.
Fig 49: Locating Lower Bellhousing Bolts
Courtesy of FORD MOTOR CO.
NOTE: The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.
61. Remove the 2 transaxle-to-engine bolts.
Fig 50: Locating Engine-To-Bellhousing Bolts
Courtesy of FORD MOTOR CO.
62. Using the special tools, secure the engine to the lift table.
Fig 51: Securing Engine To Lift Table Using Special Tool (014-0001, 014-00765)
Courtesy of FORD MOTOR CO.
63. Remove the engine mount bracket bolt.
Fig 52: Engine Mount Bracket Bolt
Courtesy of FORD MOTOR CO.
64. Remove the nuts and the engine mount bracket.
Fig 53: Engine Mount Bracket Nuts
Courtesy of FORD MOTOR CO.
65. Remove the bolt from the transaxle rear mount.
Fig 54: Transaxle Rear Mount Bolt
Courtesy of FORD MOTOR CO.
66. Remove the bolt from the LH transaxle mount.
Fig 55: Locating Transaxle Mount Bolt
Courtesy of FORD MOTOR CO.
67. Lower the engine and transaxle from the vehicle.
68. Disconnect the starter terminals.
    1. Remove the battery cable nut.
    2. Remove the starter solenoid terminal nut.
Fig 56: Identifying Battery Cable & Starter Solenoid Terminal Nut
Courtesy of FORD MOTOR CO.
69. Remove the wire harness clip retainer and the ground wire from the starter bolts.
Fig 57: Locating Wire Harness Clip Retainer & Starter Bolts
Courtesy of FORD MOTOR CO.
70. Remove the 2 stud bolts and remove the starter.
Fig 58: Identifying Stud Bolts
Courtesy of FORD MOTOR CO.
71. Remove the starter motor isolator.
Fig 59: Identifying Starter Motor Isolator
Courtesy of FORD MOTOR CO.

AWD vehicles 

72. Remove the 2 lower catalytic converter bolts.
Fig 60: Locating Lower Catalytic Converter Bolts
Courtesy of FORD MOTOR CO.
73. Remove the 6 bolts and the catalytic converter heat shield.
Fig 61: Locating Heat Shield & Bolts
Courtesy of FORD MOTOR CO.
74. Remove and discard the 7 exhaust manifold nuts.
Fig 62: Locating Exhaust Manifold Nuts
Courtesy of FORD MOTOR CO.
75. Remove the catalytic converter and discard the exhaust manifold gasket.
76. Remove and discard the 7 exhaust manifold studs.
77. Remove the 3 PTU bracket-to-engine bolts.
Fig 63: Identifying Bracket-To-Engine Bolts
Courtesy of FORD MOTOR CO.
78. Remove the 2 PTU bracket-to-PTU bolts and remove the bracket.
Fig 64: Identifying Bracket-To-PTU Bolts And Bracket
Courtesy of FORD MOTOR CO.
79. Detach the PTU vent hose retainer.
Fig 65: Identifying PTU Vent Hose Retainer
Courtesy of FORD MOTOR CO.
80. Remove the transaxle-to-PTU bolt.
Fig 66: Identifying Transaxle-To-PTU Bolt
Courtesy of FORD MOTOR CO.
81. Remove the 3 PTU-to-transaxle bolts and the PTU.
Fig 67: Identifying PTU-To-Transaxle Bolts And PTU
Courtesy of FORD MOTOR CO.

All vehicles 

82. Remove and discard the 4 torque converter nuts.
Fig 68: Locating Torque Converter Nut
Courtesy of FORD MOTOR CO.
83. Using the engine crane and spreader bar, remove the engine and transaxle from the lift table.
NOTE: The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.
84. Remove the remaining 6 engine-to-transaxle bolts and separate the engine and transaxle.