Removal and Installation

WARNING: This page is about a different car, the 2004 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.

Drain the cooling system. For additional information, refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING - 2.3L .
Remove the coolant bypass hose from the routing clip.

Fig 1: Removing Coolant Bypass Hose From Routing Clip
Courtesy of FORD MOTOR CO.
Disconnect the hose from the coolant bypass tube.

Fig 2: Disconnecting Hose From Coolant Bypass Tube
Courtesy of FORD MOTOR CO.
Remove the shifter, for manual transmission only. For additional information refer to MANUAL TRANSAXLE/TRANSMISSION .
Remove the rear driveshaft. For additional information refer to DRIVESHAFT .
Remove the catalytic converter to muffler bolts.

Fig 3: Removing Catalytic Converter To Muffler Bolts
Courtesy of FORD MOTOR CO.
Remove the bolts and the catalytic converter.

Fig 4: Removing Catalytic Converter
Courtesy of FORD MOTOR CO.

NOTE: Manual transmission shown, automatic transmission similar.

Fig 5: Supporting Transmission With Appropriate Transmission Jack

Courtesy of FORD MOTOR CO.

Support transmission with appropriate transmission jack.
Remove the six bolts (three on each side) retaining the crossmember to the frame.

Fig 6: Removing Six Bolts Retaining Crossmember To Frame
Courtesy of FORD MOTOR CO.
Detach the transmission electrical connector from the crossmember. Remove the transmission mount nuts and crossmember.

Fig 7: Removing Transmission Mount Nuts And Crossmember
Courtesy of FORD MOTOR CO.
Lower the transmission to access coolant bypass hose.
Disconnect the hose from the coolant outlet pipe and remove.

Fig 8: Removing Hose From Coolant Outlet Pipe
Courtesy of FORD MOTOR CO.
To install, reverse the removal procedure.