Special Tool(s)

WARNING: This page is about a different car, the 2005 Mercury Montego and 2005 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.

SPECIAL TOOL(S) CHART

	Lifting Bracket Set, Engine (3.0L 4V-V6) 134-00243 or equivalent
	Engine Lifting Bracket Set 303-1140
	Support Bar, Engine 303-290A
	Adapters for 303-290 303-290-01
	Adapter for 303-290A (Support Leg) 303-290A-03A
	Adapter for 303-290A (Lifting Hook) 303-290A-12

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
Remove the battery and battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
Remove the air cleaner and the outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
Remove the cowl panel grille. For additional information, refer to FRONT END BODY PANELS .
Remove the upper roll restrictor bolt.

Fig 1: Identifying Upper Roll Restrictor
Courtesy of FORD MOTOR CO.
Remove the 4 roll restrictor brace bolts and the brace.

Fig 2: Identifying Transaxle Roll Restrictor Bar Bolts
Courtesy of FORD MOTOR CO.
Disconnect the shift cable end.

Fig 3: Disconnecting Shift Cable End
Courtesy of FORD MOTOR CO.
Remove the electrical connector from the shift cable bracket.

Fig 4: Locating Electrical Connector At Shift Cable Bracket
Courtesy of FORD MOTOR CO.
Remove the 3 bolts for the shift cable bracket and position the cable and bracket aside.

Fig 5: Removing Bolts For Shift Cable Bracket
Courtesy of FORD MOTOR CO.
Disconnect the wire harness from the transmission control module (TCM).

Fig 6: Disconnecting Wire Harness From Transmission Control Module (TCM)
Courtesy of FORD MOTOR CO.
Disconnect the wire harness from the transaxle.

Fig 7: Locating Wire Harness At Transaxle
Courtesy of FORD MOTOR CO.
Disconnect the lower wire harness from the transaxle.

Fig 8: Disconnecting Lower Wire Harness From Transaxle
Courtesy of FORD MOTOR CO.
Remove the 4 bolts and the roll restrictor bracket.

Fig 9: Removing Bolts And Roll Restrictor Bracket
Courtesy of FORD MOTOR CO.
Disconnect the wire harness from the roll restrictor.

Fig 10: Locating Wire Harness At Roll Restrictor
Courtesy of FORD MOTOR CO.
Remove the positive crankcase ventilation (PCV) hose.

Fig 11: Removing Positive Crankcase Ventilation (PCV) Hose
Courtesy of FORD MOTOR CO.
Disconnect the vacuum hoses from the throttle body.

Fig 12: Disconnecting Vacuum Hoses From Throttle Body
Courtesy of FORD MOTOR CO.
Remove the bolt for the power steering line bracket and position aside.

Fig 13: Removing Bolt For Power Steering Line Bracket
Courtesy of FORD MOTOR CO.
Remove the plastic electrical cover for the starter motor electrical connectors.

Fig 14: Identifying Electrical Cover For Starter Motor Electrical Connectors
Courtesy of FORD MOTOR CO.
Disconnect the 2 starter motor electrical connectors.

Fig 15: Identifying Starter Motor Electrical Connectors
Courtesy of FORD MOTOR CO.
Remove the 2 bolts for the starter and the starter.

Fig 16: Removing Bolts For Starter
Courtesy of FORD MOTOR CO.

NOTE: It is not necessary to completely remove the roll restrictor from the vehicle, it only has to be positioned aside.

Fig 17: Removing Retaining Bolts

Courtesy of FORD MOTOR CO.

Remove the 2 retaining bolts and remove the roll restrictor and position aside.
Disconnect the ground wire.

Fig 18: Disconnecting Ground Wire
Courtesy of FORD MOTOR CO.
Remove the 4 upper transaxle bolts.

Fig 19: Removing Upper Transaxle Bolts
Courtesy of FORD MOTOR CO.
If a transaxle exchange or overhaul is required, the transmission fluid must be drained.
- Remove the drain plug and allow the fluid to drain.
  
  Fig 20: Removing Drain Plug
  Courtesy of FORD MOTOR CO.
Remove the LH and RH halfshafts. For additional information, refer to FRONT DRIVE HALFSHAFTS .
If removed, install the transmission fluid drain plug.
- Tighten to 47 Nm (35 lb-ft).
  
  Fig 21: Installing Transmission Fluid Drain Plug
  Courtesy of FORD MOTOR CO.
Remove and discard the 2 nuts for the front exhaust pipe.

Fig 22: Identifying Exhaust Pipe Nuts
Courtesy of FORD MOTOR CO.
Remove and discard the 2 nuts for the rear exhaust pipe.

Fig 23: Identifying Nuts For Rear Exhaust Pipe
Courtesy of FORD MOTOR CO.
Remove and discard the 2 nuts for the catalytic converter pipe, disconnect the rubber hanger and remove the pipe.

Fig 24: Identifying Nuts For Catalytic Converter Pipe
Courtesy of FORD MOTOR CO.
If equipped, disconnect the engine block heater electrical connector.

Fig 25: Locating Engine Block Heater
Courtesy of FORD MOTOR CO.
Position the heat shield for the knock sensor (KS) aside.

Fig 26: Identifying Heat Shield Over Knock Sensor
Courtesy of FORD MOTOR CO.
Remove the bolt and the KS.

Fig 27: Locating Knock Sensor
Courtesy of FORD MOTOR CO.
Disconnect the KS wire harness from the transaxle.

Fig 28: Disconnecting KS Wire Harness From Transaxle
Courtesy of FORD MOTOR CO.
Remove the transaxle-to-engine bolt.

Fig 29: Removing Transaxle-To-Engine Bolt
Courtesy of FORD MOTOR CO.
Remove the bolt for the power steering hose.

Fig 30: Removing Bolt For Power Steering Hose
Courtesy of FORD MOTOR CO.

NOTE: When installing the lifting bracket, it will be easier to loosely install the upper bolt first, then install the lower bolt.

Fig 31: Identifying Lower Half Of Lifting Hook

Courtesy of FORD MOTOR CO.

Install the lower half of the lifting hook.
Install the upper half of the lifting hook.

Fig 32: Identifying Upper Half Of Lifting Hook
Courtesy of FORD MOTOR CO.
Disconnect the vapor tube from the canister purge valve.

Fig 33: Disconnecting Vapor Tube From Canister Purge Valve
Courtesy of FORD MOTOR CO.
Remove the bolt for the power steering hose.

Fig 34: Removing Bolt For Power Steering Hose
Courtesy of FORD MOTOR CO.
Install the special tool to the RH cylinder head.

Fig 35: Installing Special Tool To RH Cylinder Head
Courtesy of FORD MOTOR CO.
Remove and discard the 2 bolts for the catalytic converter.

Fig 36: Locating Bolts For Catalytic Converter
Courtesy of FORD MOTOR CO.
Install the special tool to the LH cylinder head.

Fig 37: Installing Special Tool To LH Cylinder Head
Courtesy of FORD MOTOR CO.
Install the special tools to support the engine assembly.

Fig 38: Identifying Special Tools To Support Engine Assembly
Courtesy of FORD MOTOR CO.
Install the special tools to the LH (front) cylinder head.

Fig 39: Installing Special Tools To LH (Front) Cylinder Head
Courtesy of FORD MOTOR CO.
Install the special tools to the RH (rear) cylinder head.

Fig 40: Installing Special Tools To RH (Rear) Cylinder Head
Courtesy of FORD MOTOR CO.
Install the special tools into the lifting hook near the EGR valve.

Fig 41: Identifying Special Tools In Lifting Hook Near EGR Valve
Courtesy of FORD MOTOR CO.
Disconnect the lower radiator hose from the retainers and position the hose aside.

Fig 42: Disconnecting Lower Radiator Hose From Retainers
Courtesy of FORD MOTOR CO.
Remove the 4 bolts retaining the power steering line to the subframe.

Fig 43: Removing Bolts Retaining Power Steering Line To Subframe
Courtesy of FORD MOTOR CO.
Disconnect the wire harness from the LH front of the subframe.

Fig 44: Disconnecting Wire Harness From LH Front Of Subframe
Courtesy of FORD MOTOR CO.
Remove the bolts and nuts for the power steering rack. Using mechanic's wire, hold the power steering rack up and out of the way.

Fig 45: Removing Bolts And Nuts For Power Steering Rack
Courtesy of FORD MOTOR CO.
Disconnect the HO2S electrical connector from the subframe.

Fig 46: Disconnecting Ho2S Electrical Connector From Subframe
Courtesy of FORD MOTOR CO.
Disconnect the 3 pushpins and position the splash shield aside.

Fig 47: Disconnecting Pushpins
Courtesy of FORD MOTOR CO.
Remove the nut for the front motor mount.

Fig 48: Removing Nut For Front Motor Mount
Courtesy of FORD MOTOR CO.
Remove the 2 bolts for the lower stabilizer mount.

Fig 49: Removing Bolts For Lower Stabilizer Mount
Courtesy of FORD MOTOR CO.
Remove the nut for the rear motor mount.

Fig 50: Removing Nut For Rear Motor Mount
Courtesy of FORD MOTOR CO.
Remove and discard the bolts for the rear transaxle mount.

Fig 51: Identifying Bolts For Rear Transaxle Mount
Courtesy of FORD MOTOR CO.
Remove the 2 bolts for the LH rear subframe mount.

Fig 52: Removing Bolts For LH Rear Subframe Mount
Courtesy of FORD MOTOR CO.
Remove the 2 bolts for the RH rear subframe mount.

Fig 53: Removing Bolts For RH Rear Subframe Mount
Courtesy of FORD MOTOR CO.
Remove and discard the LH and RH stabilizer bar link nuts and separate the stabilizer bar links from the struts.

Fig 54: Identifying Stabilizer Bar Link Nuts
Courtesy of FORD MOTOR CO.
Using a suitable powertrain lift, remove the 4 subframe bolts and the subframe.

Fig 55: Removing Subframe Bolts And Subframe
Courtesy of FORD MOTOR CO.
Disconnect the HO2S electrical connector.

Fig 56: Disconnecting HO2S Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the bolt for the catalytic converter bracket and remove the catalytic converter.

Fig 57: Locating Bolt At Catalytic Converter Bracket
Courtesy of FORD MOTOR CO.
Remove the 2 pushpins and the rubber access plug.

Fig 58: Locating Rubber Access Plug
Courtesy of FORD MOTOR CO.
Remove and discard the 4 torque converter nuts.

Fig 59: Identifying Torque Converter Nuts
Courtesy of FORD MOTOR CO.
Disconnect the transmission fluid cooler tube bracket from the transaxle.

Fig 60: Disconnecting Transmission Fluid Cooler Tube Bracket From Transaxle
Courtesy of FORD MOTOR CO.
Disconnect the transmission fluid cooler tubes from the transaxle.

Fig 61: Disconnecting Transmission Fluid Cooler Tubes From Transaxle
Courtesy of FORD MOTOR CO.

NOTE: Make sure that the transmission is securely fastened to the transmission jack.

Position a suitable high-lift transmission jack under the transmission.
Remove the 3 transaxle-to-engine bolts.

Fig 62: Locating Transaxle-To-Engine Bolts
Courtesy of FORD MOTOR CO.
Remove the transaxle from under the vehicle.
If installing a new transaxle, the fluid cooler tubes will need to be backflushed and cleaned. Carry out transmission fluid cooler tube backflushing and cleaning. For additional information, refer to TRANSMISSION FLUID COOLER TUBES - BACKFLUSHING AND CLEANING .
If the transaxle is to be overhauled or if installing a new transaxle, a new transmission fluid cooler will need to be installed. For additional information, refer to TRANSAXLE/TRANSMISSION COOLING .
If installing a new transaxle, remove the rear transaxle mount.

Fig 63: Identifying Upper Transaxle Mount Retaining Bolts
Courtesy of FORD MOTOR CO.