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Section 394 (Manual Transmission): Removal: Transmission

WARNING: This page is about a different car, the 2002 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Identifying Special Tool(s)
G02153560Courtesy of FORD MOTOR CO.
  1. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  2. Remove the upper gearshift lever and the outer gearshift lever boot and console assembly as an assembly. For additional information, refer to SHIFT LEVER & BOOT .
  3. Raise and support the vehicle.
  4. If transmission disassembly is necessary, remove the drain plug, and drain the transmission fluid.
    • Install the drain plug after draining all of the fluid.
    Fig 2: Removing/Installing Drain Plug
    G02153561Courtesy of FORD MOTOR CO.
  5. Disconnect the electrical connector from the reversing lamp switch.
    Fig 3: Disconnecting Reversing Lamp Switch Electrical Connector
    G02153562Courtesy of FORD MOTOR CO.
  6. Disconnect the following:
    1. Disconnect the electrical connector from the Vehicle Speed Sensor (VSS).
    2. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector from the bracket.
    Fig 4: Disconnecting VSS & HO2S Electrical Connectors
    G02153563Courtesy of FORD MOTOR CO.
  7. Disconnect the wiring harness from the bracket.
    Fig 5: Disconnecting Wiring Harness From Bracket
    G02153564Courtesy of FORD MOTOR CO.
  8. Disconnect the electrical connectors from the Heated Oxygen Sensors (HO2S).
    Fig 6: Disconnecting HO2S Electrical Connector (1 Of 2)
    G02153565Courtesy of FORD MOTOR CO.
    Fig 7: Disconnecting HO2S Electrical Connector (2 Of 2)
    G02153566Courtesy of FORD MOTOR CO.
  9. Remove the starter motor. For additional information, refer to STARTERS .
    10. CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the yoke from the flange. Pry only in the area shown, with a suitable tool, to disconnect the yoke from the flange.
    CAUTION: If equipped, always disconnect the front driveshaft from the transfer case first. Otherwise, the weight of the driveshaft can cause the boot to tear.
    Fig 8: Removing Rear Driveshaft
    G02153567Courtesy of FORD MOTOR CO.
  10. Remove the rear driveshaft, and the front driveshaft, if so equipped. For additional information, refer to DRIVE SHAFTS .
  11. Remove the bolts retaining the exhaust inlet crossover pipe to the exhaust manifold.
    Fig 9: Removing Exhaust Inlet Crossover Pipe Bolts (1 Of 2)
    G02153568Courtesy of FORD MOTOR CO.
    Fig 10: Removing Exhaust Inlet Crossover Pipe Bolts (2 Of 2)
    G02153569Courtesy of FORD MOTOR CO.
  12. Remove the bolts retaining the catalytic converter to the muffler. Discard the exhaust converter outlet gasket.
    Fig 11: Removing Catalytic Converter-To-Muffler
    G02153570Courtesy of FORD MOTOR CO.
  13. While supporting the exhaust inlet crossover pipe and the catalytic converter assembly, remove the exhaust hanger from the insulator. Position the exhaust assembly aside.
    Fig 12: Removing Exhaust Hanger From Insulator
    G02153571Courtesy of FORD MOTOR CO.
  14. On 4-wheel drive vehicles, remove the transfer case. For additional information, refer to TRANSFER CASE - AUTOMATIC SHIFT .
  15. Using the special tool, disconnect the clutch hydraulic line from the clutch slave cylinder.
    Fig 13: Disconnecting Clutch Hydraulic Line From Clutch Slave Cylinder
    G02153572Courtesy of FORD MOTOR CO.
    16. WARNING: Secure the transmission to the jack with a suitable safety strap. Failure to follow these instructions may result in personal injury.
    Fig 14: Supporting Transmission
    G02153573Courtesy of FORD MOTOR CO.
  16. Using a suitable transmission jack, support the transmission. Secure the transmission to the jack with a suitable safety strap.
  17. Loosen, but do not remove the nuts retaining the transmission insulator to the crossmember.
    Fig 15: Loosening Transmission Insulator Bolts
    G02153574Courtesy of FORD MOTOR CO.
  18. Remove the six bolts retaining the crossmember to the frame.
    Fig 16: Removing Crossmember-To-Frame Bolts
    G02153575Courtesy of FORD MOTOR CO.
  19. Remove the nuts and the crossmember.
    Fig 17: Removing Crossmember
    G02153576Courtesy of FORD MOTOR CO.
    20. NOTE: Lower the transmission enough to gain access to the upper bolts retaining the transmission to the engine.
  20. Remove the nine bolts retaining the transmission to the engine.
  21. Remove the transmission from the vehicle.
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