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Transaxle - 2.3L: Removal

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.

    All vehicles 

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Remove the battery and the battery tray. For additional information, refer to REMOVAL AND INSTALLATION .
  3. Remove the air cleaner as an assembly.
    1. Remove the bolt.
    2. Disconnect the mass air flow (MAF) sensor electrical connector.
    3. Disconnect the brake booster vacuum hose.
    4. Disconnect the wiring harness retainer.
    5. Disconnect the breather tube.
    6. Loosen the clamp and remove the air cleaner assembly.
      Fig 1: Identifying Air Cleaner Assembly
      G04619971Courtesy of FORD MOTOR CO.

    4. All wheel drive (AWD) vehicles 

  4. Disconnect the power transfer unit (PTU) vent hose from the clip located on the fill tube.
    Fig 2: Locating Power Take-Off (PTO) Vent Hose
    G04619972Courtesy of FORD MOTOR CO.

    5. All vehicles 

  5. Remove the nut holding the wiring harness bracket and unplug the bulkhead electrical connector.
    Fig 3: Locating Wire Harness Bracket Nut
    G04619973Courtesy of FORD MOTOR CO.
  6. Remove the 2 bolts from the shift cable bracket and disconnect the shift cable from the manual lever.
    Fig 4: Locating Shift Cable From Manual Lever
    G04619974Courtesy of FORD MOTOR CO.
  7. Disconnect the transmission range (TR) sensor electrical connector.
    Fig 5: Locating Transmission Range (TR) Sensor Electrical Connector
    G03897857Courtesy of FORD MOTOR CO.
  8. Remove the 3 upper transaxle retaining bolts.
    Fig 6: Locating Upper Transaxle Retaining Bolts
    G04619976Courtesy of FORD MOTOR CO.
  9. Install the special tools.
    Fig 7: Identifying Installation Special Tool (1 Of 2)
    G04619977Courtesy of FORD MOTOR CO.
  10. Install the special tools.
    Fig 8: Identifying Installation Special Tool (2 Of 2)
    G04619978Courtesy of FORD MOTOR CO.
  11. Remove the LH transaxle mount through bolt.
    Fig 9: Locating LH Transaxle Mount Through Bolt
    G04619979Courtesy of FORD MOTOR CO.
  12. Remove the 2 nuts, the bolt and the through bolt and remove the rear transaxle mount.
    Fig 10: Locating Rear Transaxle Mount Bolts
    G04619980Courtesy of FORD MOTOR CO.

    13. AWD vehicles 

  13. Remove the 6 bolts holding the driveshaft to the PTO.
    Fig 11: Locating Driveshaft & Bolts
    G04619981Courtesy of FORD MOTOR CO.
  14. Remove the 2 center bearing nuts and position the driveshaft aside with mechanic's wire.
    Fig 12: Locating Center Bearing Nuts
    G04619982Courtesy of FORD MOTOR CO.

    15. All vehicles 

  15. Remove the 4 bolts and remove the cross brace.
    Fig 13: Locating Cross Brace & Bolts
    G03900713Courtesy of FORD MOTOR CO.
  16. Remove the 7 retainers and the LH splash shield.
    Fig 14: View Of LH Splash Shield And Retainers
    G03900504Courtesy of FORD MOTOR CO.
  17. Remove the 5 retainers and the RH splash shield.
    Fig 15: Locating Retainers & RH Splash Shield
    G04619985Courtesy of FORD MOTOR CO.
  18. Remove the bolt for the mount and the 2 bolts from the cross brace.
    Fig 16: Identifying Front Roll Restrictor Bolt & Bolts For Engine Support Crossmember
    G04619986Courtesy of FORD MOTOR CO.
  19. Remove and discard the nut and remove the cross brace.
    Fig 17: Identifying Cross Brace And Rear Nut
    G03897887Courtesy of FORD MOTOR CO.
    20. NOTE: If transmission disassembly or installation of a new transmission is necessary, the transmission fluid will need to be drained.
    Fig 18: Identifying Transaxle Drain Plug
    G03900626Courtesy of FORD MOTOR CO.
  20. Remove the drain plug and drain the fluid.
  21. Remove and discard the LH front axle wheel hub nut.
    Fig 19: Locating LH Front Axle Wheel Hub Nut
    G04619989Courtesy of FORD MOTOR CO.
  22. Remove the frame bolt from the LH and RH control arms.
    Fig 20: Locating Frame Bolt
    G04619990Courtesy of FORD MOTOR CO.
  23. Using the special tool, separate the LH half shaft from the front wheel knuckle.
    Fig 21: Separating LH Half Shaft From Front Wheel Knuckle Using Special Tools
    G04619991Courtesy of FORD MOTOR CO.
  24. Using the special tools, remove the LH halfshaft and disconnect the RH halfshaft from the intermediate shaft.
    Fig 22: Removing RH Outer Halfshaft Using Special Tools
    G04619992Courtesy of FORD MOTOR CO.
  25. Remove the 2 intermediate shaft retaining nuts.
    Fig 23: Locating Intermediate Shaft Retaining Nuts
    G04619993Courtesy of FORD MOTOR CO.
  26. Remove the intermediate shaft.
    Fig 24: Locating Intermediate Shaft
    G04619994Courtesy of FORD MOTOR CO.
  27. Remove the 2 bolts which hold the exhaust bracket to the intermediate shaft bracket.
    Fig 25: Locating Intermediate Shaft Bracket Bolts
    G04619995Courtesy of FORD MOTOR CO.
  28. Remove the 2 nuts on the other end of the exhaust-to-intermediate shaft bracket and remove the bracket.
    Fig 26: Locating Intermediate Shaft Bracket Nut
    G04619996Courtesy of FORD MOTOR CO.
  29. Remove the 3 nuts and separate the flexpipe from the exhaust manifold.
    Fig 27: Locating Exhaust Manifold & Nuts
    G04619997Courtesy of FORD MOTOR CO.

    30. AWD vehicles 

  30. Remove the 6 bolts holding the engine bracket to the PTU and remove the bracket.
    Fig 28: Locating Engine Bracket Bolts
    G04619998Courtesy of FORD MOTOR CO.
  31. Remove the 3 bolts and the PTU assembly.
    Fig 29: Locating PTO Bolts
    G04619999Courtesy of FORD MOTOR CO.

    32. Front wheel drive (FWD) vehicles 

  32. Remove the 3 bolts and the dampener.
    Fig 30: Locating Bolts & Dampener
    G04620000Courtesy of FORD MOTOR CO.

    33. All vehicles 

  33. Remove the 3 bolts holding the transaxle front mount plate.
    Fig 31: Locating Transaxle Front Mount Plate Bolts
    G04620001Courtesy of FORD MOTOR CO.
  34. Remove the fluid cooler line.
    Fig 32: Locating Transmission Fluid Cooler Tube
    G03897859Courtesy of FORD MOTOR CO.
  35. Remove the fluid cooler tube.
    1. Disconnect the output shaft speed (OSS) sensor electrical connector (black).
    2. Disconnect the turbine shaft speed (TSS) sensor electrical connector (white).
      • Disconnect the wiring harness retainer from the transmission case and position the harness aside.
    3. Remove the transmission fluid cooler line retaining bracket bolt.
    4. Remove the fluid cooler tube and position it aside.
      Fig 33: Locating Turbine Shaft Speed Sensor Electrical Connector
      G04620003Courtesy of FORD MOTOR CO.
  36. Remove the OSS sensor.
    Fig 34: Locating OSS Sensor Bolt
    G03897862Courtesy of FORD MOTOR CO.
  37. Disconnect the starter terminals.
    1. Remove the battery cable nut.
    2. Remove the starter solenoid terminal nut.
      Fig 35: Identifying Starter Solenoid Terminal Nut
      G04620005Courtesy of FORD MOTOR CO.
  38. Remove the wire harness clip retainer and the ground wire from the starter bolts.
    Fig 36: Locating Wire Harness Clip Retainer & Starter Bolts
    G04620006Courtesy of FORD MOTOR CO.
  39. Remove the 3 bolts and remove the starter.
    Fig 37: Locating Starter Bolts
    G04620007Courtesy of FORD MOTOR CO.
  40. Remove the starter motor isolator.
    Fig 38: Identifying Starter Motor Isolator
    G03897895Courtesy of FORD MOTOR CO.
  41. Remove and discard the 4 torque converter nuts.
    Fig 39: Locating Torque Converter Nut
    G03897896Courtesy of FORD MOTOR CO.
  42. Using the special tool, lower the transmission.
    Fig 40: Lowering Transmission Using Special Tools
    G04620010Courtesy of FORD MOTOR CO.
  43. Push the converter back from the flexplate. Use a suitable transmission jack to support the transaxle and remove the 3 rear bellhousing bolts.
    Fig 41: Locating Rear Bellhousing Bolts
    G04620011Courtesy of FORD MOTOR CO.
  44. Remove the 4 remaining transaxle-to-engine bolts.
    Fig 42: Locating Transaxle-To-Engine Bolts
    G04620012Courtesy of FORD MOTOR CO.
    45. CAUTION: The torque converter is heavy. Install the special tool before lowering the transaxle.
    Fig 43: Identifying Special Tool
    G03900854Courtesy of FORD MOTOR CO.
  45. Move the transaxle back far enough to install the special tool.
  46. Lower the transaxle from the engine compartment.
    Fig 44: Identifying Lowering Transaxle From Engine Compartment
    G04620014Courtesy of FORD MOTOR CO.
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