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Home >> Ford >> 2006 >> Focus ZX5 SE, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 60 (Engine - 6.0L Diesel -- F250-F550 Super Duty) >> In-Vehicle Repair >> Engine Rear Cover >> Removal

Engine Rear Cover: Removal

WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

    Vehicles with automatic transmission 

  1. Remove the starter. For additional information, refer to STARTING SYSTEM - DIESEL ENGINE .

    2. All vehicles 

  2. Remove the transmission. For additional information, refer to AUTOMATIC TRANSAXLE/TRANSMISSION - TORQSHIFT for automatic transmission or MANUAL TRANSAXLE/TRANSMISSION - ZF 6-SPEED for manual transmission.

    3. Vehicles with manual transmission 

  3. Remove the clutch disc and pressure plate. For additional information, refer to CLUTCH .

    4. All vehicles 

  4. Remove the bolts and the flexplate or flywheel.
    • Discard the bolts.
      Fig 1: Identifying Flexplate/Flywheel Bolts
      G03887287Courtesy of FORD MOTOR CO.
    5. NOTE: Use extreme care when removing the flywheel front adapter to prevent damage to the alignment dowel pin.
    Fig 2: Identifying Flywheel Front Adapter
    G03887288Courtesy of FORD MOTOR CO.
  5. Remove the flywheel front adapter.
    6. CAUTION: To prevent engine damage, do not remove the rear primary crankshaft flange bolts under any circumstances. If the flange is removed and reinstalled, it will result in the engine vibration and premature transmission component wear.
    NOTE: The drill bit used must be the appropriate size for the body dent puller used in the following step.
    Fig 3: Locating Drill Holes
    G03887289Courtesy of FORD MOTOR CO.
  6. Using the appropriate drill bit, drill a hole on the RH side of the seal and another directly across from it on the LH side of the seal, as shown.
    7. NOTE: It will be necessary to alternate between the two holes, drilled in the previous step, to walk the seal out of the engine rear cover.
    Fig 4: Removing Rear Main Seal Using Special Tool
    G03887290Courtesy of FORD MOTOR CO.
  7. Using the special tool and a commercially available body dent puller attachment, remove and discard the rear main seal.
    8. NOTE: Production engines will not have a wear sleeve.
    Fig 5: Removing Crankshaft Rear Wear Sleeve
    G03887291Courtesy of FORD MOTOR CO.
  8. If equipped with a crankshaft wear sleeve, use the special tool to remove the crankshaft rear wear sleeve.
  9. Clean and inspect the crankshaft sealing surface.
    Fig 6: Inspecting Crankshaft Sealing Surface
    G03887292Courtesy of FORD MOTOR CO.
  10. If equipped with a heat shield bracket, remove the retaining nuts from the heat shield bracket.
    • Disconnect the ground wire from the stud.
      Fig 7: Identifying Ground Wire Retaining Nuts
      G03906757Courtesy of FORD MOTOR CO.
  11. If equipped with a heat shield bracket, disconnect the wiring retainer from the heat shield bracket.
    Fig 8: Locating Wiring Retainer At Back Of Heat Shield Bracket
    G03906758Courtesy of FORD MOTOR CO.
  12. If equipped with a heat shield bracket, remove the bolts and heat shield bracket.
    Fig 9: Locating Bolts And Heat Shield Bracket
    G03906759Courtesy of FORD MOTOR CO.
    13. NOTE: Early build shown, late build similar.
    Fig 10: Locating Turbocharger Heat Shield And Bolts
    G03887333Courtesy of FORD MOTOR CO.
  13. Remove the bolts for the turbocharger heat shield. Position aside or remove the turbocharger heat shield.
    14. CAUTION: To prevent engine damage, replace damaged or missing dowel pins before installing the rear engine cover.
    Fig 11: Removing Bolts From Rear Engine Cover
    G03887334Courtesy of FORD MOTOR CO.
  14. Remove the 11 bolts from the rear engine cover.
    15. NOTE: Use care when removing the engine rear cover so that the oil pump cover gasket is not pulled out on removal.
    Fig 12: Cutting Sealant Using Thin-Blade Scraper
    G03921492Courtesy of FORD MOTOR CO.
  15. Using a thin-blade scraper, cut the sealant at the oil pump cover joint.
    16. CAUTION: Sealant is used where the crankcase and the lower crankcase meet. Failure to cut the sealant could result in pulling the lower crankcase seal out while removing the rear cover.
    NOTE: A 5-1/2-inch long thin-blade scraper will be needed to correctly cut the sealant.
    Fig 13: Cutting Sealant
    G03887336Courtesy of FORD MOTOR CO.
  16. Use a thin-blade scraper to cut the sealant where the crankcase and the lower crankcase meet.
    17. CAUTION: Sealant is used where the crankcase and the lower crankcase meet. Failure to cut the sealant could result in pulling the lower crankcase seal out while removing the rear cover.
    NOTE: A 5-1/2-inch long thin-blade scraper will be needed to correctly cut the sealant.
  17. Use a thin-blade scraper to cut the sealant where the crankcase and the lower crankcase meet. Remove the rear cover.
    • Remove and discard the press-in-place gasket.
    • Clean and inspect the sealing surfaces.
      Fig 14: Cutting Sealant
      G03887337Courtesy of FORD MOTOR CO.
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