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Engine - Manual Transaxle

WARNING: This page is about a different car, the 2008 Mercury Mariner and 2008 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
Special Tools

Illustration Tool Name Tool Number
GF0009877Courtesy of FORD MOTOR CO.
 Front Drive Halfshaft Remover 205-241 (T86P-3514-A)
GF0000536Courtesy of FORD MOTOR CO.
 Heavy Duty Floor Crane 014-00071 or equivalent
GF0017081Courtesy of FORD MOTOR CO.
 Powertrain Lift 014-00765
GF0000218Courtesy of FORD MOTOR CO.
 Slide Hammer 100-001 (T50T-100-A)
GF0000267Courtesy of FORD MOTOR CO.
 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
GF0010812Courtesy of FORD MOTOR CO.
 Tie-Rod End Remover 211-105 (T85M-3395-A)
GF0024108Courtesy of FORD MOTOR CO.
 Universal Adapter Brackets 014-0001
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
  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.
    10. Fig 1: Heated Oxygen Sensor (HO2S) And Catalyst Monitor Sensor Electrical Connectors
    GF0024109Courtesy 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.
    12. Fig 2: Identifying Locking Tab
    GF0042036Courtesy 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.
    13. Fig 3: Generator Shield
    GF0024111Courtesy of FORD MOTOR CO.
  13. Remove the 4 bolts and the lateral support crossmember.
    14. Fig 4: Identifying Lateral Support Crossmember And Bolts
    G03897847Courtesy of FORD MOTOR CO.
  14. Remove the brake hose retainer and the ABS sensor retaining bolt from the LH strut.
    15. Fig 5: Identifying Bolt
    GF0042037Courtesy 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.
    16. Fig 6: Identifying Stabilizer Bar Link, Retaining Nut And Knuckle Bolt
    GF0042038Courtesy of FORD MOTOR CO.
  16. Remove the brake hose retainer and the ABS sensor retaining bolt from the RH strut.
    17. Fig 7: Identifying Bolt
    GF0042039Courtesy 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.
    18. Fig 8: Identifying Stabilizer Bar Link, Retaining Nut And Knuckle Bolt
    GF0042040Courtesy of FORD MOTOR CO.
  18. Using the special tool, disconnect the LH and RH tie rod end from the steering knuckle.
    19. Fig 9: Disconnecting LH And RH Tie Rod End From Steering Knuckle
    GF0024860Courtesy of FORD MOTOR CO.
  19. Separate the LH and RH lower control arms and disconnect the steering knuckle from the lower ball joint and position the steering knuckle 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.
    22. Fig 10: Removing RH Outer Halfshaft Using Special Tools
    GF0024825Courtesy of FORD MOTOR CO.
  22. Remove the 2 intermediate shaft retaining nuts.
    23. Fig 11: Locating Intermediate Shaft Retaining Nuts
    GF0024826Courtesy of FORD MOTOR CO.
  23. Remove the intermediate shaft.
    24. Fig 12: Locating Intermediate Shaft
    GF0024827Courtesy of FORD MOTOR CO.
  24. Remove the power distribution box (PDB) cover.
    25. Fig 13: Locating Power Distribution Box Cover
    G03897849Courtesy of FORD MOTOR CO.
  25. Remove the nut and the cable from the PDB.
    26. Fig 14: Identifying Nut
    GF0042041Courtesy of FORD MOTOR CO.
  26. Disconnect the electrical connector from the PDB.
    27. Fig 15: Power Distribution Box Electrical Connector
    GF0024113Courtesy of FORD MOTOR CO.
  27. Remove the bolt and ground strap.
    28. Fig 16: Identifying Bolt
    GF0042042Courtesy of FORD MOTOR CO.
  28. Disconnect the 34-pin electrical connector.
    29. Fig 17: Identifying Connector
    GF0042043Courtesy of FORD MOTOR CO.
  29. Detach the wiring harness retainers from the battery tray bracket and position the wiring harness aside.
    30. Fig 18: Wiring Harness Retainers
    GF0024114Courtesy of FORD MOTOR CO.
  30. Position the clutch hydraulic line aside.
    1. Remove the clutch hydraulic line bracket-to-transaxle bolt.
    2. Disconnect the clutch hydraulic line from the clutch slave cylinder.
      • Plug the hydraulic line.
    3. Position the clutch hydraulic line aside.
    31. Fig 19: Clutch Hydraulic Line & Components
    GF0025335Courtesy of FORD MOTOR CO.
  31. Remove the wiring harness bracket nut and position aside
    32. Fig 20: Identifying Bracket And Nut
    GF0042055Courtesy of FORD MOTOR CO.
  32. Disconnect the vehicle speed sensor (VSS) electrical connector and pin-type retainers.
    33. Fig 21: Locating Vehicle Speed Sensor (VSS) Electrical Connector
    GF0024147Courtesy of FORD MOTOR CO.
  33. Disconnect the reversing lamp indicator switch.
    34. Fig 22: Identifying Reversing Lamp Indicator Switch
    GF0042056Courtesy of FORD MOTOR CO.
  34. Disconnect the shift cables.
    35. Fig 23: Shift Cables
    GF0025334Courtesy of FORD MOTOR CO.
  35. Remove the 3 shift cable bracket bolts.
    • Position the bracket aside.
    36. Fig 24: Shift Cable Bracket & Bolts
    GF0025336Courtesy of FORD MOTOR CO.
  36. If equipped, disconnect the block heater electrical connector.
    • Detach all the block heater wiring harness retainers and position the wiring harness aside.
    37. Fig 25: Block Heater Electrical Connector
    GF0024121Courtesy of FORD MOTOR CO.
  37. Disconnect the upper radiator hose.
    38. Fig 26: Identifying Upper Radiator Hose
    GF0042046Courtesy of FORD MOTOR CO.
  38. Detach the heater hose support strap from the stud.
    39. Fig 27: Heater Hose Support Strap & Stud
    GF0024124Courtesy of FORD MOTOR CO.
  39. Disconnect the heater hoses from the heater core.
    40. Fig 28: Locating Heater Hoses
    G03897868Courtesy of FORD MOTOR CO.
  40. Remove the retainers and the accelerator cable snow shield.
    41. Fig 29: Accelerator Cable Snow Shield Retainers
    GF0024125Courtesy of FORD MOTOR CO.
  41. 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.
    42. Fig 30: Accelerator Cable, Speed Control Cable & Bracket Bolts
    GF0024126Courtesy of FORD MOTOR CO.
  42. Remove the nut from the accelerator control cable bracket.
    • Position the accelerator control cable and bracket assembly aside.
    43. Fig 31: Accelerator Control Cable Bracket & Nut
    GF0024128Courtesy of FORD MOTOR CO.
  43. Remove the nut from the accelerator control cable bracket.
    44. Fig 32: Accelerator Control Cable Bracket & Nut
    GF0024127Courtesy of FORD MOTOR CO.
  44. Disconnect the vacuum supply tube and position aside.
    45. Fig 33: Vacuum Supply Tube
    GF0024130Courtesy of FORD MOTOR CO.
  45. Disconnect the fuel vapor return tube and position aside.
    46. Fig 34: Fuel Vapor Return Tube
    GF0024131Courtesy of FORD MOTOR CO.
  46. Disconnect the fuel supply tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
    47. Fig 35: Identifying Fuel Supply Tube
    GF0042047Courtesy of FORD MOTOR CO.
  47. Detach the electrical connector retainers.
    48. Fig 36: Electrical Connector Retainers
    GF0024134Courtesy of FORD MOTOR CO.
  48. Remove the bolt and detach the ground wire.
    49. Fig 37: Locating Ground Wire & Bolt
    G03897880Courtesy of FORD MOTOR CO.
  49. Disconnect the PCM electrical connectors.
    • Remove the wiring harness retainer nut.
    50. Fig 38: Identifying Connectors And Nut
    GF0042048Courtesy of FORD MOTOR CO.
  50. Disconnect the lower radiator hose from the radiator.
    51. Fig 39: Locating Lower Radiator Hose
    G03897882Courtesy of FORD MOTOR CO.
  51. Disconnect the A/C compressor electrical connector and remove the 3 bolts.
    • Position the A/C compressor aside and support the compressor with a length of mechanic's wire.
    52. Fig 40: A/C Compressor Electrical Connector & Bolts
    GF0024135Courtesy of FORD MOTOR CO.
  52. Remove the front roll restrictor bolt and the 2 bolts for the engine support crossmember.
    53. Fig 41: Identifying Front Roll Restrictor Bolt & Bolts For Engine Support Crossmember
    G04619986Courtesy of FORD MOTOR CO.
  53. Remove the rear nut and the engine support crossmember.
    • Discard the nut.
    54. Fig 42: Identifying Cross Brace And Rear Nut
    G03897887Courtesy of FORD MOTOR CO.
    NOTE: The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.
  54. Remove the 2 transaxle-to-engine bolts.
    55. Fig 43: Locating Lower Bellhousing Bolts
    GF0024137Courtesy of FORD MOTOR CO.
    NOTE: The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.
  55. Remove the 2 engine-to-transaxle bolts.
    56. Fig 44: Locating Engine-To-Bellhousing Bolts
    GF0024138Courtesy of FORD MOTOR CO.
  56. Using the special tools, secure the engine to the lift table.
    57. Fig 45: Securing Engine To Lift Table Using Special Tool (014-0001, 014-00765)
    G03897890Courtesy of FORD MOTOR CO.
  57. Remove the engine mount bracket bolt.
    58. Fig 46: Engine Mount Bracket Bolt
    GF0024401Courtesy of FORD MOTOR CO.
  58. Remove the nuts and the engine mount bracket.
    59. Fig 47: Engine Mount Bracket Nuts
    GF0024402Courtesy of FORD MOTOR CO.
  59. Remove the bolt from the transaxle rear mount.
    60. Fig 48: Transaxle Rear Mount Bolt
    GF0024141Courtesy of FORD MOTOR CO.
  60. Remove bolt from the LH transaxle mount.
    61. Fig 49: Locating Transaxle Mount Bolt
    G03897894Courtesy of FORD MOTOR CO.
  61. Lower the engine and transaxle from the vehicle.
  62. Disconnect the starter terminals.
    1. Remove the battery cable nut.
    2. Remove the starter solenoid terminal nut.
    63. Fig 50: Identifying Battery Cable & Starter Solenoid Terminal Nut
    GF0024836Courtesy of FORD MOTOR CO.
  63. Remove the wire harness clip retainer and the ground wire from the starter bolts.
    64. Fig 51: Locating Wire Harness Clip Retainer & Starter Bolts
    GF0024837Courtesy of FORD MOTOR CO.
  64. Remove the 2 stud bolts and remove the starter.
    65. Fig 52: Identifying Stud Bolts
    GF0042049Courtesy of FORD MOTOR CO.
  65. Using the engine crane and spreader bar, remove the engine and transaxle from the lift table.
    66. NOTE: The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.
  66. Remove the remaining 5 engine-to-transaxle bolts and separate the engine and transaxle.
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