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Section 2011 (Automatic Transmission - (Hybrid)): Removal: Transaxle

WARNING: This page is about a different car, the 2007 Mercury Mariner and 2007 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
Special Tools

Illustration Tool Name Tool Number
GF0000536
 Heavy Duty Floor Crane 014-00071 or equivalent
GF0000267
 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
GF0017081
 Powertrain Lift 014-00765
GF0024108
 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.
WARNING: To prevent exposure to high voltage, do not for any reason open the electronically controlled, continuously variable transmission (eCVT) cover. Failure to follow these instructions may result in personal injury.

All vehicles 

  1. With the vehicle in DRIVE, position it on a hoist. For additional information, refer to JACKING AND LIFTING article.
  2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
  3. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
    4. CAUTION: Before removing the high voltage cables, the vehicle electrical system must be completely shut down for at least 5 minutes to allow for the high voltage capacitors to discharge.
  4. Disable the vehicle high voltage electrical system. For additional information, refer to HIGH VOLTAGE TRACTION BATTERY article.
  5. Drain the engine cooling system. For additional information, refer to ENGINE COOLING - HYBRID article.
  6. Drain the motor electronics cooling system. For additional information, refer to TRANSAXLE/TRANSMISSION COOLING - HYBRID article.
  7. Remove the engine air cleaner. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - HYBRID article.
  8. Remove the intake manifold. For additional information, refer to ENGINE - 2.3L HYBRID article.
  9. Remove the catalytic converter. For additional information, refer to EXHAUST SYSTEM article.
  10. Remove the engine coolant degas bottle. For additional information, refer to ENGINE COOLING - HYBRID article.
  11. Remove the LH front drive halfshaft. For additional information, refer to FRONT DRIVE HALFSHAFTS article.
  12. Remove the front drive intermediate halfshaft. For additional information, refer to FRONT DRIVE HALFSHAFTS article.
  13. Remove the bolts and the lateral support crossmember.
    14. Fig 1: Identifying Lateral Support Crossmember And Bolts
    G03897847Courtesy of FORD MOTOR CO.

    4WD vehicles 

  14. Remove the driveshaft. For additional information, refer to DRIVESHAFT article.
  15. Remove the 3 transfer case heat shield bolts and the transfer case heat shield.
    16. Fig 2: Transfer Case Heat Shield & Bolts
    GF0025217Courtesy of FORD MOTOR CO.
  16. Remove the bolts and the transfer case-to-engine bracket.
    17. Fig 3: Transfer Case-To-Engine Bracket Bolts
    GF0025218Courtesy of FORD MOTOR CO.
  17. Disconnect the transfer case vent hose and position it aside.
    18. Fig 4: Transfer Case Vent Hose
    GF0025219Courtesy of FORD MOTOR CO.
  18. Remove the 4 transfer case-to-transaxle bolts and remove the transfer case.
    19. Fig 5: Transfer Case-To-Transaxle Bolts
    GF0025220Courtesy of FORD MOTOR CO.

    All vehicles 

  19. Disconnect the heater hoses from the heater core.
    20. Fig 6: Locating Heater Hoses
    G03897868Courtesy of FORD MOTOR CO.
  20. Detach the heater hose retaining clip from the transaxle mount stud.
    21. Fig 7: Heater Hose Retaining Clip
    GF0024376Courtesy of FORD MOTOR CO.
  21. Disconnect the upper radiator and coolant vent hoses.
    22. Fig 8: Upper Radiator & Coolant Vent Hoses
    GF0024377Courtesy of FORD MOTOR CO.
  22. Disconnect the engine control harness.
    • Release the powertrain control module (PCM) connector.
    • Remove the harness retaining nut.
    23. Fig 9: Powertrain Control Module (PCM) Connector & Nut
    GF0025221Courtesy of FORD MOTOR CO.
  23. Disconnect the engine control harness electrical connector and the pin-type retainer.
    24. Fig 10: Engine Control Harness Electrical Connector
    GF0025222Courtesy of FORD MOTOR CO.
  24. Remove the selector lever cable fasteners from the stud bolts on the transaxle.
    25. Fig 11: Selector Lever Cable Fasteners
    GF0025223Courtesy of FORD MOTOR CO.
  25. Remove the bolt and disconnect the transaxle harness electrical connector.
    26. Fig 12: Transaxle Harness Electrical Connector & Bolt
    GF0024381Courtesy of FORD MOTOR CO.
  26. Disconnect the 2 low voltage electrical connectors and the engine harness-to-body harness retainer.
    27. Fig 13: Low Voltage Electrical Connectors
    GF0025224Courtesy of FORD MOTOR CO.
  27. Disconnect the DC-to-DC converter electrical connector and the harness retainers.
    28. Fig 14: DC-To-DC Converter Electrical Connector
    GF0024382Courtesy of FORD MOTOR CO.
  28. Remove the 3 nuts and position aside the DC-to-DC converter.
    29. Fig 15: DC-To-DC Converter & Nuts
    GF0024383Courtesy of FORD MOTOR CO.
    NOTE: Parts removed from view for clarity.
  29. If equipped, position the block heater wiring harness aside.
    • Detach the 3 harness retainer clips.
    • Route the harness through the radiator support into the engine compartment.
    30. Fig 16: Block Heater Wiring Harness
    GF0024385Courtesy of FORD MOTOR CO.
  30. Remove the 2 bolts and disconnect the auxiliary coolant pump electrical connector. Position the auxiliary coolant pump aside.
    31. Fig 17: Auxiliary Coolant Pump Electrical Connector & Bolts
    GF0024386Courtesy of FORD MOTOR CO.
  31. Disconnect the electrical connector and the wiring harness retainer from the steering gear.
    32. Fig 18: Steering Gear Electrical Connector
    GF0025225Courtesy of FORD MOTOR CO.
  32. Remove the bolts and the transaxle control splash shield.
    33. Fig 19: Transaxle Control Splash Shield
    GF0024387Courtesy of FORD MOTOR CO.
  33. Disconnect the transaxle control cable.
    • Release the transaxle control cable from the control lever.
    • Remove the nuts from the transaxle control cable bracket.
    34. Fig 20: Selector Lever Cable Bracket Nuts
    GF0024388Courtesy of FORD MOTOR CO.
  34. Disconnect the selector lever cable from the retainer.
    35. Fig 21: Selector Lever Cable At Retainer
    GF0025226Courtesy of FORD MOTOR CO.
  35. Disconnect the motor electronics coolant temperature sensor electrical connector and pin-type retainer.
    36. Fig 22: Motor Electronics Coolant Temperature Sensor Electrical Connector
    GF0024391Courtesy of FORD MOTOR CO.
  36. Disconnect the transaxle coolant hoses.
    37. Fig 23: Transaxle Coolant Hoses
    GF0024392Courtesy of FORD MOTOR CO.
  37. Remove the 2 harness fasteners, the nut and the ground cable.
    38. Fig 24: Ground Cable
    GF0025227Courtesy of FORD MOTOR CO.
  38. Remove the 2 bolts and position the motor electronics coolant pump and ground strap aside.
    39. Fig 25: Motor Electronics Coolant Pump & Ground Strap
    GF0024394Courtesy of FORD MOTOR CO.
  39. Disconnect the lower radiator hose from the radiator.
    40. Fig 26: Locating Lower Radiator Hose
    G03897882Courtesy of FORD MOTOR CO.
  40. Remove the bolts and position the A/C compressor aside using a suitable length of mechanic's wire.
    41. Fig 27: A/C Compressor Bolts
    GF0025228Courtesy of FORD MOTOR CO.
  41. Remove the front roll restrictor bolt.
    42. Fig 28: Front Roll Restrictor Bolt
    GF0024396Courtesy of FORD MOTOR CO.
  42. Remove the rear roll restrictor bracket bolts.
    43. Fig 29: Rear Roll Restrictor Bracket Bolts
    GF0025229Courtesy of FORD MOTOR CO.
  43. Remove the nut, bolts and the engine support crossmember.
    44. Fig 30: Engine Support Crossmember & Fasteners
    GF0024398Courtesy of FORD MOTOR CO.
    NOTE: The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.
  44. Remove the 2 transaxle-to-engine bolts.
    45. Fig 31: Transaxle-To-Engine Bolts
    GF0024399Courtesy of FORD MOTOR CO.
    NOTE: The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.
  45. Remove the 2 transaxle-to-engine bolts.
    46. Fig 32: Transaxle-To-Engine Bolts
    GF0024400Courtesy of FORD MOTOR CO.
    NOTE: Due to the weight of the transaxle, special care should be taken to mount the powertrain securely to the lift table.
  46. Using the special tools, secure the engine to the lift table.
    47. Fig 33: Securing Engine To Lift Table Using Special Tool (014-0001, 014-00765)
    G03897890Courtesy of FORD MOTOR CO.
  47. Remove the engine mount bracket bolt.
    48. Fig 34: Engine Mount Bracket Bolt
    GF0024401Courtesy of FORD MOTOR CO.
  48. Remove the nuts and the engine mount bracket.
    49. Fig 35: Engine Mount Bracket Nuts
    GF0024402Courtesy of FORD MOTOR CO.
  49. Remove the RH transaxle mount bracket nut.
    50. Fig 36: Right Transaxle Mount Bracket Nut
    GF0024403Courtesy of FORD MOTOR CO.
  50. Remove the bolts and the RH transaxle mount bracket.
    51. Fig 37: Right Transaxle Mount Bracket Bolts
    GF0024404Courtesy of FORD MOTOR CO.
  51. Remove the bolts and the rear transaxle mount brace.
    52. Fig 38: Rear Transaxle Mount Brace & Bolts
    GF0024405Courtesy of FORD MOTOR CO.
  52. Remove the nuts, bolt and rear transaxle mount.
    53. Fig 39: Rear Transaxle Mount & Fasteners
    GF0024406Courtesy of FORD MOTOR CO.
  53. Lower the engine and transaxle from the vehicle.
  54. Using the engine crane and spreader bar, remove the engine and transaxle from the lift table.
  55. Disconnect the high voltage wiring harness electrical connector.
    56. Fig 40: High Voltage Wiring Harness Electrical Connector
    GF0024407Courtesy of FORD MOTOR CO.
  56. Remove the wiring harness retainers and the wiring harness from the transaxle cover stud bolts.
    57. Fig 41: Wiring Harness Retainers
    GF0025230Courtesy of FORD MOTOR CO.
    NOTE: The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.
  57. Remove the remaining 6 engine-to-transaxle bolts and separate the engine and transaxle.
    58. CAUTION: The damper contains a clutch which designed to slip briefly during vehicle operation. It is essential that no grease, oil or cleaning solvents be allowed to contaminate the slip clutch. Do not use grease on transmission input shaft or input shaft splines.

    Should the damper become contaminated it must be replaced.

    NOTE: Due to packaging requirements, the correct bolt must be used at the damper locations.
  58. Remove the bolts and the transaxle damper.
    59. Fig 42: Transaxle Damper Bolts
    GF0024409Courtesy of FORD MOTOR CO.
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