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Home >> Ford >> 2006 >> Focus ZX5 SE, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1559 (Manual Transaxle) >> Removal >> Transaxle >> Special Tool(s)

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.
G07786564
 Powertrain Lift
300-OTC1585AE or equivalent
G07786565
 Support Bar, Engine
303-F072
WARNING: Do not breathe dust or use compressed air to blow dust from storage containers or friction components. Remove dust using government-approved techniques. Friction component dust may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or may lead to other chronic health effects. If irritation persists, seek medical attention or advice. 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. Remove the battery tray. For additional information, refer to BATTERY, MOUNTING & CABLES -- FUSION, MILAN & MKZ article.
  3. Remove the Air Cleaner (ACL) assembly. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING - 2.5L -- FUSION & MILAN (EXCEPT HYBRID) article.
  4. Disconnect the shift cables from the transaxle shift control lever, using a suitable tool to lightly pry them off the transaxle shift control lever.
    Fig 1: Locating Shift Cables And Transaxle Shift Control Lever
    G07786566Courtesy of FORD MOTOR CO.
    5. NOTE: Carefully pry the retainer on the shift cables. Do not damage the shift cable retainers. Using a small screwdriver push from the back.
    Fig 2: Locating Transaxle Bracket Shift Cables
    G07786567Courtesy of FORD MOTOR CO.
  5. Disconnect the shift cables from the transaxle bracket.
  6. Install the Engine Support Bar.
    Fig 3: Identifying Engine Support Bar
    G07786568Courtesy of FORD MOTOR CO.
  7. Detach the wire harness from the transaxle.
  8. Remove the 3 upper transaxle-to-engine bolts.
    9. NOTE: If one or both of the mount studs are removed or come out, do not reinstall the old stud(s). Install a new stud(s). Make sure the studs are properly seated in the case, even if they were not replaced.
  9. Remove the transaxle rear support insulator nuts and the transaxle rear support insulator bolt.
    10. NOTE: Use a steering wheel holding device such as Hunter® 28-75-1 or equivalent, to hold the steering wheel.
    Fig 4: Holding Steering Wheel
    G07786569Courtesy of FORD MOTOR CO.
  10. Using a suitable holding device, hold the steering wheel in the straight-ahead position.
  11. Remove the 2 nuts and the steering joint cover.
    Fig 5: Locating Steering Joint Cover And Mounting Nuts
    G07786570Courtesy of FORD MOTOR CO.
    12. 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 6: View Of Steering Column Shaft Mounting Bolt
    G07786571Courtesy of FORD MOTOR CO.
  12. Remove and discard the bolt and disconnect the steering column shaft from the steering gear.
  13. If equipped, remove the 7 screws and the underbody cover.
    Fig 7: Locating Splash Shield Bolts
    G07786572Courtesy of FORD MOTOR CO.
    14. NOTE: If disassembly of the transaxle is required, remove the drain plug and drain the transaxle.
    Fig 8: Locating Transaxle Drain Plug
    G07786573Courtesy of FORD MOTOR CO.
  14. Remove the drain plug and drain the transaxle.
  15. Once fluid has drained, install the drain plug.
    • Tighten to 49 Nm (36 lb-ft).
  16. Remove the 2 clutch tube hydraulic line bracket bolts.
    Fig 9: Locating Clutch Tube Hydraulic Line Bracket Bolts
    G07786574Courtesy of FORD MOTOR CO.
  17. Remove the 2 bolts and position the clutch slave cylinder aside.
    Fig 10: Locating Clutch Slave Cylinder Mounting Bolts
    G07786575Courtesy of FORD MOTOR CO.
  18. Disconnect the reverse lamp switch electrical connector.
  19. Remove the starter motor. For additional information, refer to STARTING SYSTEM article.
  20. Disconnect the Output Shaft Speed (OSS) electrical connector.
    Fig 11: View Of Vehicle Speed Sensor (VSS) Electrical Connector
    G07786576Courtesy of FORD MOTOR CO.
    21. NOTE: Remove the steering gear/dash seal or damage to the seal may occur.
    Fig 12: Locating Steering Gear/Dash Seal Mounting Clips
    G07786577Courtesy of FORD MOTOR CO.
  21. Release the 4 clips and slide the steering gear/dash seal off of the steering gear.
  22. Remove the exhaust flexible pipe. For additional information, refer to EXHAUST SYSTEM -- FUSION, MILAN & MKZ article.
  23. Remove the 2 roll restrictor bracket bolts.
    Fig 13: Locating Roll Restrictor Bracket Bolts
    G07786578Courtesy of FORD MOTOR CO.
  24. Remove the 4 screws and position the RH fender splash shield aside.
    Fig 14: Locating RH Fender Splash Shield Mounting Screws
    G07786579Courtesy of FORD MOTOR CO.
  25. Remove the 6 pin-type retainers (4 shown in illustration) and the RH splash shield.
    Fig 15: Locating RH Fender Splash Shield 6 Pin-Type Retainers
    G07786580Courtesy of FORD MOTOR CO.
  26. Remove the 4 screws and position the LH fender splash shield aside.
    Fig 16: Locating LH Fender Splash Shield Mounting Screws
    G07786581Courtesy of FORD MOTOR CO.
  27. Remove the 6 pin-type retainers (4 shown in illustration) and the LH splash shield.
    Fig 17: Locating LH Fender Splash Shield 6 Pin-Type Retainers
    G07786582Courtesy of FORD MOTOR CO.
  28. Remove the LH halfshaft and the intermediate shaft. For additional information, refer to FRONT DRIVE HALFSHAFTS article.
  29. Disconnect the 2 in-line Electronic Power Assist Steering (EPAS) system electrical connectors at the front of the subframe.
    Fig 18: Locating Electronic Power Assist Steering System Electrical Connectors
    G07786583Courtesy of FORD MOTOR CO.
  30. Detach the 2 EPAS system wiring harness pin-type retainers from the subframe.
    Fig 19: Locating EPAS System Wiring Harness Pin-Type Retainers
    G07786584Courtesy of FORD MOTOR CO.
  31. Detach the EPAS system wiring harness pin-type retainer from the subframe under the LH fender splash shield.
    Fig 20: Locating LH Fender Splash Shield Retainer
    G07786585Courtesy of FORD MOTOR CO.
  32. Remove the bolt and the EPAS system wiring harness ground from behind the RH splash shield.
    Fig 21: Locating EPAS System Wiring Harness Ground Mounting Bolt
    G07786586Courtesy of FORD MOTOR CO.
    33. NOTE: LH shown in illustration, RH similar.
    Fig 22: Locating Stabilizer Bar Links Nuts
    G07786587Courtesy of FORD MOTOR CO.
  33. Remove the nuts and separate the stabilizer bar links from the struts.
  34. Position the Powertrain Lift under the subframe assembly.
    Fig 23: Positioning Powertrain Lift Under Subframe Assembly
    G07786588Courtesy of FORD MOTOR CO.
    35. NOTE: LH shown in illustration, RH similar.
    Fig 24: Locating Subframe Bracket-To-Body Bolts
    G07786589Courtesy of FORD MOTOR CO.
  35. Remove the subframe bracket-to-body bolts.
    36. NOTE: LH shown in illustration, RH similar.
    Fig 25: Locating Rear Subframe Nut
    G07786590Courtesy of FORD MOTOR CO.
  36. Remove the rear subframe nuts and the subframe brackets.
    37. NOTE: LH shown in illustration, RH similar.
    Fig 26: Locating Front Subframe Nut
    G07786591Courtesy of FORD MOTOR CO.
  37. Remove the front subframe nuts.
  38. Lower the subframe assembly from the vehicle.
  39. Support the transaxle with a suitable transmission jack. Secure the transaxle to the transmission jack with a safety strap.
  40. Remove the clutch housing-to-oil pan bolt.
    Fig 27: Locating Clutch Housing-To-Oil Pan Bolt
    G07786592Courtesy of FORD MOTOR CO.
  41. Remove the 2 oil pan-to-clutch housing bolts.
    Fig 28: Locating Oil Pan-To-Clutch Housing Bolts
    G07786593Courtesy of FORD MOTOR CO.
  42. Remove the remaining 4 transaxle-to-engine bolts.
  43. Move the transaxle away from the engine and lower it from the vehicle.
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