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Special Tool(s)

WARNING: This page is about a different car, the 2011 Mercury Milan and 2011 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL(S)

G07780798
 2,200# Floor Crane, Fold Away
300-OTC1819E or equivalent
G07780799
 Powertrain Lift
300-OTC1585AE or equivalent
G07780800
 Remover, Tie-Rod End
211-105
G07780801
 Spreader Bar
303-D089 (D93P-6001-A3) or equivalent
G07780802
 Adjustable Grip Arm, 1735A
014-00001 or equivalent
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING article.
  2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - FUSION, MILAN & MKZ article.
  3. Remove the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING - 2.5L -- FUSION & MILAN (EXCEPT HYBRID) article.
  4. Recover the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION & DIAGNOSTICS -- FUSION, MILAN & MKZ (EXCEPT HYBRID) article.
  5. Remove the battery tray. For additional information, refer to BATTERY, MOUNTING & CABLES -- FUSION, MILAN & MKZ article.
  6. Remove the 2 nuts and the battery cables from the positive battery cable.
    Fig 1: Locating Battery Cables Of Positive Battery Cable With Nuts
    G07780803Courtesy of FORD MOTOR CO.
  7. Disconnect the engine wiring harness electrical connector.
    Fig 2: Locating Engine Wiring Harness Electrical Connector
    G07780804Courtesy of FORD MOTOR CO.
  8. Remove the bolt and the ground wire from the body.
    Fig 3: Locating Battery Bolt
    G07780805Courtesy of FORD MOTOR CO.
  9. Detach the 2 negative battery cable pin-type retainers from the transaxle mount and battery tray bracket.
    Fig 4: Locating Negative Battery Cable Pin-Type Retainers
    G07780806Courtesy of FORD MOTOR CO.
  10. Disconnect the 2 engine harness electrical connector.
    Fig 5: Locating Engine Harness Electrical Connector
    G07780807Courtesy of FORD MOTOR CO.
  11. Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent).
    • Using a suitable holding device, hold the steering wheel in the straight-ahead position.
    Fig 6: Holding Steering Wheel In Straight-Ahead Position Using A Suitable Holding Device
    G07780808Courtesy of FORD MOTOR CO.
  12. Remove the 2 nuts and the steering joint cover.
    Fig 7: Locating Steering Joint Cover And Nuts
    G07780809Courtesy of FORD MOTOR CO.
    13. NOTE: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring can occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to SUPPLEMENTAL RESTRAINT SYSTEM -- FUSION, MILAN & MKZ article.
    Fig 8: Locating Steering Column Shaft Bolt
    G07780810Courtesy of FORD MOTOR CO.
  13. Remove the bolt and disconnect the steering column shaft from the steering gear.
    • Discard the bolt.
  14. If equipped, remove the 7 screws and the underbody cover.
    Fig 9: Locating Underbody Cover Screws
    G07780811Courtesy of FORD MOTOR CO.
  15. Drain the cooling system. For additional information, refer to ENGINE COOLING SYSTEM (EXCEPT HYBRID) article.
    16. NOTE: The steering gear-to-dash seal must be removed or it will be damaged when lowering the subframe.
    Fig 10: Locating Steering Gear-To-Dash Seal Clips
    G07780812Courtesy of FORD MOTOR CO.
  16. Release the 4 clips (2 shown in the illustration) and slide the steering gear-to-dash seal off of the steering gear and into the passenger compartment.
  17. Remove the engine roll restrictor bolt.
    Fig 11: Locating Engine Roll Restrictor Bolt
    G07780813Courtesy of FORD MOTOR CO.
  18. Remove the 4 screws and position the RH fender splash shield aside.
    Fig 12: Locating RH Fender Splash Shield Screws
    G07780814Courtesy of FORD MOTOR CO.
  19. Remove the 6 pin-type retainers (4 shown in the illustration) and the RH splash shield.
    Fig 13: Locating Splash Shield Pin-Type Retainers
    G07780815Courtesy of FORD MOTOR CO.
  20. Remove the 4 screws and position the LH fender splash shield aside.
    Fig 14: Locating LH Fender Splash Shield Screws
    G07780816Courtesy of FORD MOTOR CO.
  21. Remove the 6 pin-type retainers (4 shown in the illustration) and the LH splash shield.
    Fig 15: Locating LH Splash Shield Pin-Type Retainers
    G07780817Courtesy of FORD MOTOR CO.
  22. Remove the LH halfshaft and the intermediate shaft. For additional information, refer to FRONT DRIVE HALFSHAFTS article.
  23. Disconnect the 2 Electronic Power Assist Steering (EPAS) system electrical connectors.
    Fig 16: Locating Electronic Power Assist Steering (EPAS) System Electrical Connectors
    G07780818Courtesy of FORD MOTOR CO.
  24. Detach the 2 EPAS system wiring harness pin-type retainers from the subframe.
    Fig 17: Locating EPAS System Wiring Harness Pin-Type Retainers Of Subframe
    G07780819Courtesy of FORD MOTOR CO.
  25. Detach the EPAS system wiring harness pin-type retainer from the subframe under the LH fender splash shield.
    Fig 18: Locating EPAS System Wiring Harness Pin-Type Retainers Of Subframe
    G07780820Courtesy of FORD MOTOR CO.
  26. Remove the bolt and the EPAS system wiring harness ground.
    Fig 19: Locating EPAS System Wiring Harness Ground Bolt
    G07780821Courtesy of FORD MOTOR CO.
    27. NOTE: LH shown in the illustration, RH similar.
    Fig 20: Locating Cotter Pin And Nut On Tie-Rod Ends
    G07780822Courtesy of FORD MOTOR CO.
  27. Remove the cotter pins and nuts from the tie-rod ends.
    28. NOTE: LH shown in the illustration, RH similar.
    Fig 21: Separating Tie-Rod Ends From Steering Knuckle Using Tie-Rod End Remover
    G07780823Courtesy of FORD MOTOR CO.
  28. Using the Tie-Rod End Remover, separate the tie-rod ends from the steering knuckles.
    29. NOTE: LH shown in the illustration, RH similar.
    Fig 22: Locating Sway Bar Link Nut
    G07780824Courtesy of FORD MOTOR CO.
  29. Remove the nuts and separate the sway bar links from the struts.
  30. Position the Powertrain Lift under the subframe assembly.
    Fig 23: Positioning Powertrain Lift Under Subframe Assembly
    G07780825Courtesy of FORD MOTOR CO.
    31. NOTE: LH shown in the illustration, RH similar.
    Fig 24: Locating Subframe Bracket-To-Body Bolts
    G07780826Courtesy of FORD MOTOR CO.
  31. Remove the subframe bracket-to-body bolts.
    32. NOTE: LH shown in the illustration, RH similar.
    Fig 25: Locating Subframe Bracket Nuts
    G07780827Courtesy of FORD MOTOR CO.
  32. Remove the rear subframe nuts and the subframe brackets.
    33. NOTE: LH shown in the illustration, RH similar.
    Fig 26: Locating Front Subframe Nuts
    G07780828Courtesy of FORD MOTOR CO.
  33. Remove the front subframe nuts.
  34. Lower the subframe assembly from the vehicle.
  35. Remove the engine oil pan drain plug and drain the engine oil.
    • Install the drain plug and tighten to 28 Nm (21 lb-ft).
    Fig 27: Locating Engine Oil Pan Drain Plug
    G07780829Courtesy of FORD MOTOR CO.
  36. Remove the engine oil filter.
  37. Remove the exhaust flexible pipe. For additional information, refer to EXHAUST SYSTEM -- FUSION, MILAN & MKZ article.
  38. Disconnect the crankcase vent tube from the valve cover.
    Fig 28: Locating Crankcase Vent Tube Of Valve Cover
    G07780830Courtesy of FORD MOTOR CO.
  39. Depress the locking ring and disconnect the brake booster vacuum supply tube from the intake manifold.
    Fig 29: Locating Brake Booster Vacuum Supply Tube Of Intake Manifold
    G07780831Courtesy of FORD MOTOR CO.
  40. Disconnect the fuel vapor return tube.
    Fig 30: Locating Fuel Vapor Return Tube
    G07780832Courtesy of FORD MOTOR CO.
  41. Disconnect the fuel supply tube quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - FUSION, MILAN & MKZ article.
    Fig 31: Locating Fuel Supply Tube Quick Connect Coupling
    G07780833Courtesy of FORD MOTOR CO.
  42. Detach the coolant hose retainer.
    Fig 32: Locating Coolant Hose Retainer
    G07780834Courtesy of FORD MOTOR CO.
  43. Disconnect the upper radiator and heater hoses from the coolant outlet and disconnect the heater hose in-line connector.
    Fig 33: Locating Heater Hoses Of Coolant Outlet
    G07780835Courtesy of FORD MOTOR CO.
  44. Disconnect the transaxle control cables from the control levers.
    • Detach the control cables from the bracket.
    Fig 34: Locating Transaxle Control Cable
    G07780836Courtesy of FORD MOTOR CO.
  45. Remove the 2 clutch tube bracket bolts.
    Fig 35: Locating Clutch Tube Bracket Bolts
    G07780837Courtesy of FORD MOTOR CO.
  46. Remove the 2 bolts and position the clutch slave cylinder aside.
    Fig 36: Locating Clutch Slave Cylinder Bolts
    G07780838Courtesy of FORD MOTOR CO.
  47. Remove the bolt and the ground wire from the engine mount.
    Fig 37: Locating Engine Mount Ground Wire And Nut
    G07780839Courtesy of FORD MOTOR CO.
  48. Remove the A/C tube/windshield washer reservoir bracket bolt.
    Fig 38: Locating A/C Tube/Windshield Washer Reservoir Bracket Bolt
    G07780840Courtesy of FORD MOTOR CO.
  49. Remove the nut and disconnect the A/C tube.
    • Discard the O-ring seal.
    Fig 39: Locating A/C Tube Nut And O-Ring Seal
    G07780841Courtesy of FORD MOTOR CO.
  50. Detach the coolant vent hose retaining clip from the A/C tube.
    Fig 40: Locating Coolant Vent Hose Retaining Clip Of A/C Tube
    G07780842Courtesy of FORD MOTOR CO.
  51. Remove the nut and disconnect the upper A/C tube from the condenser.
    • Discard the O-ring seal.
    Fig 41: Locating Condenser Upper A/C Tube Nut
    G07780843Courtesy of FORD MOTOR CO.
  52. Detach the Knock Sensor (KS) electrical connector from the intake manifold.
    Fig 42: Locating Knock Sensor (KS) Electrical Connector Of Intake Manifold
    G07780844Courtesy of FORD MOTOR CO.
  53. Remove the lower radiator hose from the thermostat housing.
    Fig 43: Locating Lower Radiator Hose Of Thermostat Housing
    G07780845Courtesy of FORD MOTOR CO.
  54. If equipped, position the block heater shield aside and disconnect the block heater electrical connector.
    • Detach the 8 block heater wiring harness retainers (1 shown in the illustration) and remove the block heater wiring harness.
    Fig 44: Locating Block Heater Wiring Harness Retainer
    G07780846Courtesy of FORD MOTOR CO.
  55. Detach the lower radiator hose pin-type retainer from the cooling fan shroud.
    Fig 45: Locating Lower Radiator Hose Pin-Type Retainer Of Cooling Fan Shroud
    G07780847Courtesy of FORD MOTOR CO.
  56. Remove the bellhousing-to-oil pan bolt.
    Fig 46: Locating Bellhousing-To-Oil Pan Bolt
    G07780848Courtesy of FORD MOTOR CO.
  57. Remove the 2 oil pan-to-bellhousing bolts.
    58. Fig 47: Locating Oil Pan-To-Bellhousing Bolts
    G07780849Courtesy of FORD MOTOR CO.
    NOTE: Position a block of wood under the transaxle.
    Fig 48: Raising Engine Using Powertrain Lift And Adjustable Grip Arm
    G07780850Courtesy of FORD MOTOR CO.
  58. Install the Powertrain Lift and Adjustable Grip Arm onto the engine.
    • Raise the engine and transaxle 25.4 mm (1 in) to neutralize the engine and transaxle mounts.
  59. Remove the 2 transaxle mount bolts.
    Fig 49: Locating Transaxle Mount Bolts
    G07780851Courtesy of FORD MOTOR CO.
  60. Remove the bolt, 2 nuts and the motor mount bracket.
    Fig 50: Locating Engine Mount Bracket, Bolts And Nuts
    G07780852Courtesy of FORD MOTOR CO.
  61. Lower the engine and transaxle from the vehicle.
  62. Disconnect the A/C compressor electrical connector.
    Fig 51: Locating A/C Compressor Electrical Connector
    G07780853Courtesy of FORD MOTOR CO.
  63. Detach the A/C compressor wiring harness pin-type retainer from the intake manifold.
    Fig 52: Locating A/C Compressor Wiring Harness Pin-Type Retainer Of Intake Manifold
    G07780854Courtesy of FORD MOTOR CO.
  64. Remove the 2 nuts and disconnect the starter wires.
    Fig 53: Locating Starter Motor Wires Nuts
    G07780855Courtesy of FORD MOTOR CO.
  65. Remove the nut from the starter motor stud bolt.
    Fig 54: Locating Starter Motor Stud Bolt Of Ground Wire And Nut
    G07780856Courtesy of FORD MOTOR CO.
  66. Remove the bolt, stud bolt and the starter.
    Fig 55: Locating Starter With Stud Bolts
    G07780857Courtesy of FORD MOTOR CO.
  67. Remove the starter motor isolator.
    Fig 56: Locating Starter Motor Isolator
    G07780858Courtesy of FORD MOTOR CO.
  68. Press the locking tab to release the generator air duct and remove.
    Fig 57: Locating Locking Tab And Generator Air Duct
    G07780859Courtesy of FORD MOTOR CO.
  69. Disconnect the generator electrical connection.
    Fig 58: Locating Generator Electrical Connection
    G07780860Courtesy of FORD MOTOR CO.
  70. Remove the nut and the generator wiring harness.
    Fig 59: Locating Nut And Generator B+ Wiring Harness
    G07780861Courtesy of FORD MOTOR CO.
  71. Detach the 4 wiring harness retainers (3 shown in the illustration) from the valve cover stud bolts.
    Fig 60: Locating Wiring Harness Retainers Of Valve Cover Stud Bolts
    G07780862Courtesy of FORD MOTOR CO.
  72. Install the Floor Crane and Spreader Bar and remove the engine and transaxle from the Powertrain Lift table.
    Fig 61: Remove/Install Engine And Transaxle From Powertrain Lift Table Using Floor Crane And Spreader Bar
    G07780863Courtesy of FORD MOTOR CO.
  73. Remove the bellhousing-to-engine retainers.
    • Separate the engine and transaxle.
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