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Engine - Automatic Transaxle

WARNING: This page is about a different car, the 2006 Mercury Mariner and 2006 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL(S)

G04618023Courtesy of FORD MOTOR CO.
 Heavy Duty Floor Crane
014-00071 or equivalent
G04618024Courtesy of FORD MOTOR CO.
 Spreader Bar
303-D089 (D93P-6001-A3) or equivalent
G04618025Courtesy of FORD MOTOR CO.
 Powertrain Lift
014-00765
G04618026Courtesy of FORD MOTOR CO.
 Universal Adapter Brackets
014-0001
Lifting Bracket Set, Engine 303-D095 (D94L-6001-A) or equivalent
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury.

    All vehicles 

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM PRESSURE RELEASE .
  3. Remove the engine air cleaner and air cleaner outlet pipe. For additional information, refer to REMOVAL AND INSTALLATION - AIR CLEANER and REMOVAL AND INSTALLATION - AIR CLEANER OUTLET PIPE .
  4. Remove the battery tray. For additional information, refer to REMOVAL AND INSTALLATION .
  5. Drain the engine oil.
  6. Drain the cooling system. For additional information, refer to DRAINING .
  7. Remove the starter. For additional information, refer to STARTING SYSTEM .
  8. Remove the exhaust flexible pipe. For additional information, refer to REMOVAL AND INSTALLATION .
  9. Disconnect the heated oxygen sensor (HO2S) and the catalyst monitor sensor electrical connectors.
    Fig 1: Locating Heated Oxygen Sensor (HO2S) & Catalyst Monitor Sensor Electrical Connectors
    G04618027Courtesy of FORD MOTOR CO.
  10. Remove the accessory drive belt tensioner. For additional information, refer to REMOVAL AND INSTALLATION .
  11. Remove the bolt and press the locking tab to release the lower air duct from the upper air duct.
    Fig 2: Locating Bolt & Lower Air Duct
    G04618028Courtesy of FORD MOTOR CO.
  12. Detach the wire retainers from the generator shield and remove the nut and pin-type retainer and remove the generator shield.
    Fig 3: Locating Nut & Pin-Type Retainer
    G04618029Courtesy of FORD MOTOR CO.
  13. Remove the LH front drive halfshafts. For additional information, refer to REMOVAL .

    14. All wheel drive (AWD) vehicles 

  14. Remove the transfer case. For additional information, refer to TRANSFER CASE-POWER TRANSFER UNIT (PTU) .

    15. Front wheel drive (FWD) vehicles 

  15. Remove the bolts and the lateral support crossmember.
    Fig 4: Identifying Lateral Support Crossmember And Bolts
    G03897847Courtesy of FORD MOTOR CO.
  16. Remove the front drive intermediate halfshaft. For additional information, refer to REMOVAL AND INSTALLATION .

    17. All vehicles 

  17. If equipped, remove the bolt and ground eyelet.
    Fig 5: Locating Bolt & Ground Eyelet
    G04618031Courtesy of FORD MOTOR CO.
  18. Remove the power distribution box cover.
    Fig 6: Locating Power Distribution Box Cover
    G03897849Courtesy of FORD MOTOR CO.
  19. Remove the nuts and disconnect the cables.
    Fig 7: Locating Cables & Nuts
    G03897850Courtesy of FORD MOTOR CO.
  20. Disconnect the electrical connector from the power distribution box.
    Fig 8: Locating Electrical Connector
    G04618034Courtesy of FORD MOTOR CO.
  21. Remove the bolt and disconnect the ground strap. Loosen the bolt and disconnect the 42-pin electrical connector.
    Fig 9: Locating Ground Strap & Electrical Connector
    G03897852Courtesy of FORD MOTOR CO.
  22. Detach the wiring harness retainers from the battery tray bracket and position the wiring harness aside.
    Fig 10: Locating Wiring Harness Retainers
    G04618036Courtesy of FORD MOTOR CO.
  23. Disconnect the transaxle electrical connector.
    Fig 11: Locating Transaxle Electrical Connector
    G04618037Courtesy of FORD MOTOR CO.
  24. Disconnect the shift cable from the transaxle manual lever.
    Fig 12: Locating Shift Cable End At Manual Lever
    G03897855Courtesy of FORD MOTOR CO.
  25. Position the transaxle control cable and bracket aside.
    • Detach the wiring harness pin-type retainer.
    • Remove the bolts and position the cable and bracket aside.
      Fig 13: Locating Transaxle Control Cable & Bolts
      G04618039Courtesy of FORD MOTOR CO.
  26. Disconnect the transmission range (TR) sensor electrical connector.
    Fig 14: Locating Transmission Range (TR) Sensor Electrical Connector
    G03897857Courtesy of FORD MOTOR CO.
  27. Detach the transaxle control harness from the brackets.
    Fig 15: Locating Transaxle Control Harness
    G04618041Courtesy of FORD MOTOR CO.
  28. Disconnect the front transmission fluid cooler tube.
    Fig 16: Locating Transmission Fluid Cooler Tube
    G03897859Courtesy of FORD MOTOR CO.
  29. Disconnect the rear transmission fluid cooler tube.
    Fig 17: Locating Rear Transmission Fluid Cooler Tube
    G04618043Courtesy of FORD MOTOR CO.
  30. Position the fluid cooler tube aside.
    1. Disconnect the output shaft speed (OSS) sensor electrical connector (black).
    2. Disconnect the turbine shaft speed (TSS) sensor electrical connector (white connector).
    3. Remove the transmission fluid cooler retaining bracket bolt.
    4. Position the fluid cooler tube aside.
      Fig 18: Identifying Fluid Cooler Tube Aside
      G04618044Courtesy of FORD MOTOR CO.
  31. Remove the bolt and the OSS sensor.
    Fig 19: Locating OSS Sensor Bolt
    G03897862Courtesy of FORD MOTOR CO.
  32. Detach the transaxle control harness from the retaining clip.
    Fig 20: Locating Transaxle Control Harness From Retaining Clip
    G04618046Courtesy of FORD MOTOR CO.
  33. If equipped, disconnect the block heater electrical connector. Detach all the block heater wiring harness retainers and position the wiring harness aside.
    Fig 21: Locating Block Heater Electrical Connector
    G04618047Courtesy of FORD MOTOR CO.
  34. Disconnect the upper radiator and coolant vent hoses.
    Fig 22: Locating Upper Radiator & Coolant Vent Hoses
    G04618048Courtesy of FORD MOTOR CO.
  35. Remove the nuts and the coolant vent hose brackets. Position the coolant vent hose aside.
    Fig 23: Locating Nuts & Coolant Vent Hose Brackets
    G04618049Courtesy of FORD MOTOR CO.
  36. Detach the heater hose support strap from the stud.
    Fig 24: Locating Heater Hose Support Strap From Stud
    G04618050Courtesy of FORD MOTOR CO.
  37. Disconnect the heater hoses from the heater core.
    Fig 25: Locating Heater Hoses
    G03897868Courtesy of FORD MOTOR CO.
  38. Remove the retainers and the accelerator cable snow shield.
    Fig 26: Locating Retainers & Accelerator Cable Snow Shield
    G04618052Courtesy of FORD MOTOR CO.
  39. 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.
      Fig 27: Identifying Accelerator Cable Bracket Bolts
      G04618053Courtesy of FORD MOTOR CO.
  40. Remove the nut from the accelerator control cable bracket.
    Fig 28: Locating Accelerator Control Cable Bracket Nut (1 Of 2)
    G04618054Courtesy of FORD MOTOR CO.
  41. Remove the nut from the accelerator control cable bracket and position the accelerator control cable and bracket assembly aside.
    Fig 29: Locating Accelerator Control Cable Bracket Nut (2 Of 2)
    G04618055Courtesy of FORD MOTOR CO.
  42. Remove the nut and position the power steering tube and bracket aside.
    Fig 30: Locating Power Steering Tube & Bracket Aside
    G04618056Courtesy of FORD MOTOR CO.
  43. Disconnect the vacuum supply tube and position aside.
    Fig 31: Locating Vacuum Supply Tube & Position Aside
    G04618057Courtesy of FORD MOTOR CO.
  44. Disconnect the fuel vapor return tube and retainer and position aside.
    Fig 32: Locating Fuel Vapor Return Tube & Retainer
    G04618058Courtesy of FORD MOTOR CO.
  45. Disconnect the vacuum reservoir tube and position aside.
    Fig 33: Locating Vacuum Reservoir Tube & Position Aside
    G04618059Courtesy of FORD MOTOR CO.
  46. Disconnect the fuel supply tube and position aside.
    Fig 34: Locating Fuel Supply Tube & Position Aside
    G04618060Courtesy of FORD MOTOR CO.
  47. Detach the electrical connector retainers.
    Fig 35: Locating Electrical Connector Retainers
    G04618061Courtesy of FORD MOTOR CO.
  48. Disconnect the powertrain control module (PCM) electrical connectors. Remove the nut and position the harness aside.
    Fig 36: Locating Powertrain Control Module (PCM) Electrical Connectors
    G03897879Courtesy of FORD MOTOR CO.
  49. Remove the bolt and detach the ground wire.
    Fig 37: Locating Ground Wire & Bolt
    G03897880Courtesy of FORD MOTOR CO.
  50. Remove the 2 power steering pump bolts.
    Fig 38: Locating Power Steering Pump Bolts
    G03897741Courtesy of FORD MOTOR CO.
  51. Disconnect the lower radiator hose from the radiator.
    Fig 39: Locating Lower Radiator Hose
    G03897882Courtesy of FORD MOTOR CO.
  52. Disconnect the A/C compressor electrical connector and remove the 4 bolts. Position the A/C compressor aside and support the compressor with a length of mechanic's wire.
    Fig 40: Locating A/C Compressor Bolts
    G04618066Courtesy of FORD MOTOR CO.
  53. Disconnect the power steering pressure (PSP) sensor electrical connector.
    Fig 41: Locating Power Steering Pressure (PSP) Sensor Electrical Connector
    G04618067Courtesy of FORD MOTOR CO.
    54. NOTE: The bolt under the power steering pressure tube will remain with the power steering pump.
    Fig 42: Identifying Power Steering Pump Bolts
    G03897742Courtesy of FORD MOTOR CO.
  54. Remove the bolts and position the power steering pump aside.
  55. Remove the front roll restrictor bolt and the 2 bolts for the engine support crossmember.
    Fig 43: Identifying Front Roll Restrictor Bolt & Bolts For Engine Support Crossmember
    G04619986Courtesy of FORD MOTOR CO.
  56. Remove the rear nut and the engine support crossmember.
    • Discard the nut.
      Fig 44: Identifying Cross Brace And Rear Nut
      G03897887Courtesy of FORD MOTOR CO.
    57. NOTE: The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.
    Fig 45: Locating Transaxle-To-Engine Bolts
    G04618071Courtesy of FORD MOTOR CO.
  57. Remove the 2 transaxle-to-engine bolts.
    58. NOTE: The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.
    Fig 46: Locating Transaxle-To-Engine Bolts
    G04618072Courtesy of FORD MOTOR CO.
  58. Remove the 2 transaxle-to-engine bolts.
  59. Using the special tools, secure the engine to the lift table.
    Fig 47: Securing Engine To Lift Table Using Special Tool (014-0001, 014-00765)
    G03897890Courtesy of FORD MOTOR CO.
  60. Remove the engine mount bracket bolt.
    Fig 48: Locating Engine Mount Bracket Bolt
    G04618074Courtesy of FORD MOTOR CO.
  61. Remove the nuts and the engine mount bracket.
    Fig 49: Locating Nuts & Engine Mount Bracket
    G04618075Courtesy of FORD MOTOR CO.
  62. Remove the bolt from the transaxle rear mount.
    Fig 50: Locating Bolt From Transaxle Rear Mount
    G04618076Courtesy of FORD MOTOR CO.
  63. Remove the bolt from the LH transaxle mount.
    Fig 51: Locating Transaxle Mount Bolt
    G03897894Courtesy of FORD MOTOR CO.
  64. Lower the engine and transaxle from the vehicle.
  65. Using the engine crane and spreader bar, remove the engine and transaxle from the lift table.
  66. Remove the starter motor isolator.
    Fig 52: Identifying Starter Motor Isolator
    G03897895Courtesy of FORD MOTOR CO.
  67. Remove and discard the 4 torque converter nuts.
    Fig 53: Locating Torque Converter Nut
    G03897896Courtesy of FORD MOTOR CO.
    68. NOTE: The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.
  68. Remove the remaining 6 engine-to-transaxle bolts and separate the engine and transaxle.
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