Section 1415 (Engine -- 4.0L SOHC): Removal: Engine: Removal

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

CAUTION: If the fuel rail is used as a leverage device, it can be damaged. Care must be taken when working around the fuel rail.

All vehicles

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING .
Disconnect the spring lock coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
Disconnect the battery cables. For additional information, refer to BATTERY, MOUNTING AND CABLES .
Remove the nut and disconnect the ground wire.

Fig 1: Disconnecting Ground Wire
Courtesy of FORD MOTOR CO.
Disconnect the electrical connector and detach the wiring harness retainers.

Fig 2: Disconnecting Electrical Connector
Courtesy of FORD MOTOR CO.
Lift the cover, remove the nut and disconnect the battery cable connector.

Fig 3: Disconnecting Battery Cable Connector
Courtesy of FORD MOTOR CO.
Drain the cooling system. For additional information, refer to ENGINE COOLING .
Recover the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
Disconnect the windshield washer hose.

Fig 4: Disconnecting Windshield Washer Hose
Courtesy of FORD MOTOR CO.

NOTE: Mark the hinge locations for installation reference.

Fig 5: Removing Bolts And Hood

Courtesy of FORD MOTOR CO.

Remove the 4 bolts and the hood.
Remove the cooling fan and shroud. For additional information, refer to ENGINE COOLING .
Remove the power steering pump pulley. For additional information, refer to POWER STEERING
Remove the air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING .
Disconnect the mass air flow (MAF) sensor electrical connector.

Fig 6: Disconnecting Mass Air Flow Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the air cleaner assembly.

Fig 7: Removing Air Cleaner Assembly
Courtesy of FORD MOTOR CO.
Disconnect the powertrain control module (PCM) electrical connectors.

Fig 8: Disconnecting Powertrain Control Module Electrical Connectors
Courtesy of FORD MOTOR CO.
Release the wiring harness from the clips on the bulkhead.

Fig 9: Releasing Wiring Harness From Clips On Bulkhead
Courtesy of FORD MOTOR CO.
Disconnect the transmission control wiring harness pin-type retainers from the engine wiring harness.

Fig 10: Disconnecting Transmission Control Wiring Harness Pin-Type Retainers From Engine Wiring Harness
Courtesy of FORD MOTOR CO.
Disconnect the evaporative emissions (EVAP) tube and position it aside.

Fig 11: Disconnecting Evaporative Emissions Tube
Courtesy of FORD MOTOR CO.
Disconnect the vacuum hose.

Fig 12: Disconnecting Vacuum Hose
Courtesy of FORD MOTOR CO.
Remove the bolt from the engine ground wire.

Fig 13: Removing Bolt From Engine Ground Wire
Courtesy of FORD MOTOR CO.
Disconnect the vacuum hose and the heater hose.

Fig 14: Disconnecting Vacuum Hose And Heater Hose
Courtesy of FORD MOTOR CO.
Disconnect the upper radiator hose and the heater hose.

Fig 15: Disconnecting Upper Radiator Hose And Heater Hose
Courtesy of FORD MOTOR CO.
Remove the bolts and position the heater hoses and bracket aside.
Disconnect the lower radiator hose at the coolant pump.

Fig 16: Disconnecting Lower Radiator Hose At Coolant Pump
Courtesy of FORD MOTOR CO.
Disconnect the coolant hoses from the degas bottle.

Fig 17: Disconnecting Coolant Hoses From Degas Bottle
Courtesy of FORD MOTOR CO.

NOTE: Cover the accumulator opening to prevent contamination.

Remove the nut and disconnect the A/C tube from the accumulator.
- Discard the O-ring seal.
  
  Fig 18: Disconnecting A/C Tube From Accumulator
  Courtesy of FORD MOTOR CO.
Remove the nut and disconnect the A/C tube from the condenser.
- Discard the O-ring seal.
  
  Fig 19: Disconnecting A/C Tube From Condenser
  Courtesy of FORD MOTOR CO.
Disconnect the vacuum hoses.

Fig 20: Disconnecting Vacuum Hoses
Courtesy of FORD MOTOR CO.
Disconnect the A/C high-pressure cut-off switch electrical connector.

Fig 21: Disconnecting A/C High-Pressure Cut-Off Switch Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the nut and disconnect the A/C tube from the condenser.
- Discard the O-ring seal.
  
  Fig 22: Disconnecting A/C Tube From Condenser
  Courtesy of FORD MOTOR CO.
Disconnect the A/C tube from the retainer.

Fig 23: Disconnecting A/C Tube From Retainer
Courtesy of FORD MOTOR CO.
Remove the exhaust manifold-to-exhaust gas recirculation (EGR) valve tube.
1. Disconnect the exhaust manifold-to-EGR valve tube fittings.
2. Remove the exhaust manifold-to-EGR valve tube.
  
  Fig 24: Removing Exhaust Manifold-To-EGR Valve Tube
  Courtesy of FORD MOTOR CO.
Remove the starter motor. For additional information, refer to STARTING SYSTEM .
Remove the push pins and the lower air shroud panel.

Fig 25: Locating Lower Air Dam Push Pins
Courtesy of FORD MOTOR CO.
Remove the nut and detach the battery cable retainer bracket.

Fig 26: Detaching Battery Cable Retainer Bracket
Courtesy of FORD MOTOR CO.

4x4 vehicles

Install a suitable jack stand under the transfer case.

Fig 27: Supporting Transfer Case With Suitable Jack Stand
Courtesy of FORD MOTOR CO.

4x2 vehicles

WARNING: Secure the transmission to the transmission jack with a safety chain. Failure to follow these instructions can result in personal injury.

Fig 28: Supporting Transmission With Transmission Jack

Courtesy of FORD MOTOR CO.

Support the transmission with a transmission jack.

All vehicles

Remove the 2 bolts and position the RH heat shield aside.

Fig 29: Removing Bolts And Positioning RH Heat Shield Aside
Courtesy of FORD MOTOR CO.

NOTE: LH shown, RH similar.

Fig 30: Locating Heated Oxygen Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

Disconnect the 2 heated oxygen sensor (HO2S) electrical connectors.

NOTE: RH shown, LH similar.

Fig 31: Identifying Catalyst Monitor Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

Disconnect the 2 catalyst monitor sensor electrical connectors.
Remove the RH heat shield bolts.

Fig 32: Removing RH Heat Shield Bolts
Courtesy of FORD MOTOR CO.
Remove the RH heat shield bolt and remove the heat shield.

Fig 33: Removing RH Heat Shield Bolt
Courtesy of FORD MOTOR CO.
Remove the LH heat shield bolt.

Fig 34: Locating LH Heat Shield Bolt
Courtesy of FORD MOTOR CO.
Remove the 2 nuts and the plastic shield on the right side of the crossmember.

Fig 35: Locating Plastic Shield On Right Side Of Crossmember Near Fuel Tank
Courtesy of FORD MOTOR CO.

NOTE: RH shown, LH similar.

Fig 36: Removing Upper Crossmember Bolts

Courtesy of FORD MOTOR CO.

Remove the 4 upper crossmember bolts.

NOTE: RH shown, LH similar.

Fig 37: Locating RH Side Crossmember Bolts

Courtesy of FORD MOTOR CO.

Remove the 4 lower crossmember bolts.

4x2 vehicles

Remove the bolts and cable bracket from the transmission.

Fig 38: Removing Bolts And Cable Bracket From Transmission
Courtesy of FORD MOTOR CO.

All vehicles

Remove the transmission support insulator nuts and remove the crossmember.

Fig 39: Identifying Transmission Support Insulator Nuts
Courtesy of FORD MOTOR CO.
Remove the bolts, springs, flag nuts and separate the muffler from the converter.
- Discard the gasket.
- Discard the flag nuts.
  
  Fig 40: Separating Muffler From Converter
  Courtesy of FORD MOTOR CO.

NOTE: LH shown, RH similar.

Fig 41: Locating Catalytic Converter-To-Manifold Nuts

Courtesy of FORD MOTOR CO.

Remove the 4 converter-to-manifold nuts.

NOTE: The assistance of another technician may be required.

Remove the transmission-mounted exhaust hanger, the 3-way converter system and the RH heat shield.
1. Remove the bolt and the converter assembly.
2. If required, remove the second bolt and mount.
  
  Fig 42: Removing Bolt And Converter Assembly
  Courtesy of FORD MOTOR CO.
Disconnect the shift cable and remove the bracket.

Fig 43: Identifying Shift Cable And Bracket
Courtesy of FORD MOTOR CO.

4x4 vehicles

Index-mark the front axle pinion flange and the front driveshaft.

Fig 44: Identifying Universal Joint Retainer Ring
Courtesy of FORD MOTOR CO.
Index-mark the front output shaft assembly and the front driveshaft constant velocity (CV) joint.

Fig 45: Identifying Index-Mark On Front Output Shaft Assembly
Courtesy of FORD MOTOR CO.
Remove and discard the bolts and washers.

Fig 46: Removing Bolts And Washers
Courtesy of FORD MOTOR CO.
Remove and discard the bolts and universal joint retainers.

Fig 47: Locating Universal Joint Retainers
Courtesy of FORD MOTOR CO.

CAUTION: Always disconnect the front driveshaft from the transfer case first. Otherwise, the weight of the driveshaft can pinch the boot and cause the boot to tear.

CAUTION: Tape the bearing cups to the driveshaft to prevent them from falling off the spider.

Fig 48: Removing Front Driveshaft

Courtesy of FORD MOTOR CO.

Remove the front driveshaft.

All vehicles

NOTE: The axle pinion flange is shown, the transfer case output flange, if equipped, is similar.

Fig 49: Identifying Index Mark Rear Output Flange And Driveshaft Yoke

Courtesy of FORD MOTOR CO.

Mark the driveshaft flange to the rear axle pinion flange, and if equipped, the transfer case rear output flange for assembly reference.
Remove the 4 rear axle flange bolts.

Fig 50: Locating Driveshaft Yoke Bolts
Courtesy of FORD MOTOR CO.

4x2 vehicles

Index-mark the driveshaft at the 6 o'clock position.

Fig 51: Identifying Index-Mark Position
Courtesy of FORD MOTOR CO.

4x4 vehicles

Remove the 4 transfer case flange bolts.

Fig 52: Removing Transfer Case Flange Bolts
Courtesy of FORD MOTOR CO.

All vehicles

CAUTION: The driveshaft flange fits tightly on the rear axle pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft flange from the pinion flange.

NOTE: Do not rotate the driveshaft.

Fig 53: Disconnecting Driveshaft Flange Yoke From Pinion Flange

Courtesy of FORD MOTOR CO.

Using a suitable tool as shown, disconnect the driveshaft flange and remove the driveshaft.

4x2 vehicles

Index-mark the transmission output shaft at the 6 o'clock position.
1. Pull the seal away from the transmission output shaft.
2. Mark the output shaft at the 6 o'clock position.
  
  Fig 54: Identifying Index-Mark Position
  Courtesy of FORD MOTOR CO.

All vehicles

Disconnect the RH catalyst monitor connector and the fuel tubes from the bracket.

Fig 55: Locating Fuel Lines And RH Catalyst Monitor Connector Bracket
Courtesy of FORD MOTOR CO.
Disconnect the RH HO2S electrical connector from the transmission.

Fig 56: Disconnecting RH HO2S Electrical Connector From Transmission
Courtesy of FORD MOTOR CO.
If equipped, disconnect the shift motor electrical connector.

Fig 57: Locating Shift Motor Electrical Connector And Wiring Harness Pin-Type Retainer
Courtesy of FORD MOTOR CO.
Disconnect the LH HO2S electrical connector retainer and the harness clip from the transmission.

Fig 58: Identifying Wire Harness Retainers
Courtesy of FORD MOTOR CO.
Disconnect the LH catalyst monitor connector from the transmission.

Fig 59: Identifying LH Catalyst Monitor Connector Retainer At Transmission
Courtesy of FORD MOTOR CO.

NOTE: Make an identifying mark on the nut, stud and flexplate to allow for correct installation.

Remove the 4 torque converter nuts.
- Rotate the crankshaft to access all the nuts.
  
  Fig 60: Removing Torque Converter Nuts
  Courtesy of FORD MOTOR CO.
Move the rubber boot back to gain access to the connector.

Fig 61: Moving Rubber Boot Back
Courtesy of FORD MOTOR CO.
Disconnect the digital transmission range sensor.

Fig 62: Locating Transmission Range (TR) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the electrical connectors.

Fig 63: Locating Electrical Connectors
Courtesy of FORD MOTOR CO.

NOTE: Clean the area around the connector to prevent contamination of the solenoid body connector.

Fig 64: Identifying Solenoid Body Electrical Connector

Courtesy of FORD MOTOR CO.

Remove the screw and disconnect the solenoid body electrical connector.
Disconnect the harness retainers.

Fig 65: Disconnecting Harness Retainers
Courtesy of FORD MOTOR CO.

CAUTION: Do not damage the cooler tubes. Hold the transmission case fitting with a wrench.

Fig 66: Locating Transmission Cooler Tubes

Courtesy of FORD MOTOR CO.

Disconnect the transmission cooler tubes.
Remove the transmission cooler tube clips

Fig 67: Removing Transmission Cooler Tube Clips
Courtesy of FORD MOTOR CO.
Using the special tool, disconnect the transmission cooler tubes.

Fig 68: Disconnecting Transmission Cooler Tubes Using Special Tool
Courtesy of FORD MOTOR CO.
Remove the nut and the cooler tubes and bracket.

Fig 69: Removing Nut And Cooler Tubes And Bracket
Courtesy of FORD MOTOR CO.

4x4 vehicles

WARNING: Secure the transmission to the jack with a safety chain. Failure to follow these instructions can result in personal injury.

Fig 70: Supporting Transmission With Transmission Jack

Courtesy of FORD MOTOR CO.

Support the transmission with a transmission jack.
Remove the jack stand from the transfer case.

Fig 71: Supporting Transfer Case With Suitable Jack Stand
Courtesy of FORD MOTOR CO.

All vehicles

Remove the 8 engine-to-transmission retaining bolts.

Fig 72: Locating Engine-To-Transmission Retaining Bolts
Courtesy of FORD MOTOR CO.
Remove the transmission.
Install the special tool.

Fig 73: Installing Special Tool
Courtesy of FORD MOTOR CO.
Disconnect the power steering return hose.

Fig 74: Disconnecting Power Steering Return Hose
Courtesy of FORD MOTOR CO.
Remove the drain plug and drain the engine oil. Remove the oil filter.
- To install, tighten to 26 Nm (19 lb-ft).
Remove the LH engine support insulator bolt.

Fig 75: Removing LH Engine Support Insulator Bolt
Courtesy of FORD MOTOR CO.
Disconnect the power steering fluid reservoir-to-fluid cooler hose and detach the clip.

Fig 76: Disconnecting Power Steering Fluid Reservoir-To-Fluid Cooler Hose And Detach Clip
Courtesy of FORD MOTOR CO.
Remove the bolt and power steering tube support bracket.

Fig 77: Removing Bolt And Power Steering Tube Support Bracket
Courtesy of FORD MOTOR CO.
Disconnect the power steering pressure (PSP) tube.
- Remove and discard the O-ring seal.
  
  Fig 78: Disconnecting Power Steering Pressure Tube
  Courtesy of FORD MOTOR CO.
Remove the RH engine support insulator nuts.

Fig 79: Removing RH Engine Support Insulator Nuts
Courtesy of FORD MOTOR CO.
Remove the bolts and the LH radiator support bracket.

Fig 80: Removing Bolts And LH Radiator Support Bracket
Courtesy of FORD MOTOR CO.
Remove the bolts and the RH radiator support bracket.

Fig 81: Removing Bolts And RH Radiator Support Bracket
Courtesy of FORD MOTOR CO.
Remove the radiator and A/C condenser as an assembly.

Fig 82: Removing Radiator And A/C Condenser Assembly
Courtesy of FORD MOTOR CO.
Install the special tool on the LH side of the engine.
- Tighten to 37 Nm (27 lb-ft).
  
  Fig 83: Installing Special Tool On LH Side Of Engine
  Courtesy of FORD MOTOR CO.
Install the special tool on the RH side of the engine.
- Tighten to 37 Nm (27 lb-ft).
  
  Fig 84: Installing Special Tool On RH Side Of Engine
  Courtesy of FORD MOTOR CO.
Attach the special tool and using a suitable floor crane, remove the engine.

Fig 85: Attaching Special Tool And Using Suitable Floor Crane
Courtesy of FORD MOTOR CO.