Engine Rear Cover: Removal

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

Remove the starter. For additional information, refer to STARTING SYSTEM - DIESEL ENGINE .
Remove the transmission. For additional information, refer to TRANSAXLE/TRANSMISSION - TORQSHIFT .
Remove the bolts and the flexplate.
- Discard the bolts.
  
  Fig 1: Identifying Flexplate/Flywheel Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Use extreme care when removing the flywheel front adapter to prevent damage to the alignment dowel pin.

Fig 2: Identifying Flywheel Front Adapter

Courtesy of FORD MOTOR CO.

Remove the flywheel front adapter.

CAUTION: To prevent engine damage, do not remove the rear primary crankshaft flange bolts under any circumstances. If the flange is removed and reinstalled, it will result in engine vibration and premature transmission component wear.

NOTE: The drill bit used must be the appropriate size for the body dent puller used in the following step.

Fig 3: Locating Drill Holes

Courtesy of FORD MOTOR CO.

Using the appropriate drill bit, drill a hole on the RH side of the seal and another directly across from it on the LH side of the seal, as shown in Fig 3.

NOTE: It will be necessary to alternate between the two holes, drilled in 5 to walk the seal out of the engine rear cover.

Fig 4: Removing Rear Main Seal Using Special Tool

Courtesy of FORD MOTOR CO.

Using the special tool and a commercially available body dent puller attachment, remove and discard the rear main seal.

NOTE: Production engines will not have a wear sleeve.

Fig 5: Removing Crankshaft Rear Wear Sleeve

Courtesy of FORD MOTOR CO.

If equipped with a crankshaft wear sleeve, use the special tool to remove the crankshaft rear wear sleeve.
Clean and inspect the crankshaft sealing surface.

Fig 6: Identifying Crankshaft Sealing Surface
Courtesy of FORD MOTOR CO.
Remove the bolts and the turbocharger heat shield.

Fig 7: Locating Turbocharger Heat Shield And Bolts
Courtesy of FORD MOTOR CO.

CAUTION: To prevent engine damage, replace damaged or missing dowel pins before installing the rear engine cover.

Fig 8: Removing Bolts

Courtesy of FORD MOTOR CO.

Remove the 11 bolts from the rear engine cover.

NOTE: Use care when removing the engine rear cover so that the oil pump cover gasket is not pulled out during removal.

Fig 9: Cutting Sealant At Oil Pump Cover Joint

Courtesy of FORD MOTOR CO.

Using a thin-blade scraper, cut the sealant at the oil pump cover joint.

CAUTION: Sealant is used where the crankcase and the lower crankcase meet. Failure to cut the sealant can result in pulling the lower crankcase seal out while removing the rear cover.

NOTE: A 5.5-inch long thin-blade scraper is needed to correctly cut the sealant.

Fig 10: Cutting Sealant

Courtesy of FORD MOTOR CO.

Using a thin-blade scraper, cut the sealant where the crankcase and the lower crankcase meet.

CAUTION: Sealant is used where the crankcase and the lower crankcase meet. Failure to cut the sealant can result in pulling the lower crankcase seal out while removing the rear cover.

NOTE: A 5.5-inch long thin-blade scraper is needed to properly cut the sealant.

Using a thin-blade scraper, cut the sealant where the crankcase and the lower crankcase meet. Remove the rear cover.
- Remove and discard the press-in-place gasket.
- Clean and inspect the sealing surfaces.
  
  Fig 11: Inspecting Sealing Surfaces
  Courtesy of FORD MOTOR CO.