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Engine - Manual Transaxle

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SPECIAL TOOL DESCRIPTION

G04680202Courtesy of FORD MOTOR CO.
 Separator, Balljoint
205-592
G04680203Courtesy of FORD MOTOR CO.
 Adapter for 204-592
204-592/1
G04680204Courtesy of FORD MOTOR CO.
 Tie-Rod End Remover
211-105
G04680205Courtesy of FORD MOTOR CO.
 Remover, Halfshaft
205-832
G04680206Courtesy of FORD MOTOR CO.
 Slide Hammer
100-001
G04680207Courtesy of FORD MOTOR CO.
 Remover, Halfshaft
205-243
G04680208Courtesy of FORD MOTOR CO.
 Heavy Duty Floor Crane
014-00071 or equivalent
G04680209Courtesy of FORD MOTOR CO.
 Spreader Bar
303-D089 (D93P-6001-A3) or equivalent
G04680210Courtesy of FORD MOTOR CO.
 Powertrain Lift
014-00765
G04680211Courtesy of FORD MOTOR CO.
 Universal Adapter Brackets
014-0001
Lifting Bracket Set, Engine 303-D095 (D94L-6001-A) or equivalent
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  3. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  4. Recover the air conditioning system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS
  5. Place the steering wheel in the straight ahead position and the ignition key in the OFF position.
  6. Remove the 2 nuts and the steering joint cover.
    Fig 1: Locating Steering Joint Cover And Nuts
    G04680212Courtesy of FORD MOTOR CO.
    7. CAUTION: 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 .
    NOTE: Index the steering column shaft position to the steering gear for reference during installation.
    Fig 2: Locating Steering Column Shaft Bolt
    G04680213Courtesy of FORD MOTOR CO.
  7. Remove the bolt and disconnect the steering column shaft from the steering gear.
  8. Remove the bolt and disconnect the power steering pressure (PSP) tube from the power steering pump.
    • Route the PSP tube out the bottom of the engine compartment.
      Fig 3: Locating Power Steering Pressure (PSP) Tube Bolt
      G04680214Courtesy of FORD MOTOR CO.
  9. Drain the cooling system. For additional information, refer to ENGINE COOLING .
  10. If equipped, remove the 7 screws and the underbody cover.
    Fig 4: Locating Underbody Cover Screws
    G04680215Courtesy of FORD MOTOR CO.
  11. Remove the exhaust flexible pipe. For additional information, refer to EXHAUST SYSTEM .
    12. CAUTION: The steering gear-to-dash seal must be removed or it will be damaged when lowering the subframe.
    Fig 5: Locating Clips
    G04680216Courtesy of FORD MOTOR CO.
  12. Release the 4 clips and slide the steering gear-to-dash seal off of the steering gear and into the passenger compartment.
  13. Remove the engine roll restrictor bolt.
    Fig 6: Locating Engine Roll Restrictor Bolt
    G04680217Courtesy of FORD MOTOR CO.
  14. Remove the 4 screws and position the RH fender splash shield aside.
    Fig 7: Locating RH Fender Splash Shield Screws
    G04684102Courtesy of FORD MOTOR CO.
  15. Remove the 6 pin-type retainers (4 shown) and the RH splash shield.
    Fig 8: Locating Splash Shield Pin-Type Retainers
    G04684103Courtesy of FORD MOTOR CO.
  16. Remove the 4 screws and position the LH fender splash shield aside.
    Fig 9: Locating LH Fender Splash Shield And Screws
    G04680220Courtesy of FORD MOTOR CO.
  17. Remove the 6 pin-type retainers (4 shown) and the LH splash shield.
    Fig 10: Locating LH Splash Shield And Pin-Type Retainers
    G04680221Courtesy of FORD MOTOR CO.
    18. NOTE: LH shown, RH similar.
    Fig 11: Locating Tie-Rod Ends Cotter Pins And Nuts
    G04680222Courtesy of FORD MOTOR CO.
  18. Remove the cotter pins and nuts from the tie-rod ends.
    19. NOTE: LH shown, RH similar.
    Fig 12: Locating Special Tool
    G04680223Courtesy of FORD MOTOR CO.
  19. Using the special tool, separate the tie-rod ends from the steering knuckles.
  20. Disconnect the power steering cooler tube.
    Fig 13: Locating Power Steering Cooler Tube
    G04680224Courtesy of FORD MOTOR CO.
    21. NOTE: LH shown, RH similar.
    Fig 14: Locating Sway Bar Links Nut
    G04680225Courtesy of FORD MOTOR CO.
  21. Remove the nuts and separate the sway bar links from the struts.
    22. NOTE: LH shown, RH similar.
    Fig 15: Locating Lower Ball Joint Nuts
    G04680226Courtesy of FORD MOTOR CO.
  22. Remove the lower ball joint nuts.
    23. CAUTION: When the lower ball joint is separated from the wheel knuckle, the lower arm may strike the outer constant velocity (CV) joint boot with enough force to damage the boot clamp. This will result in a loss of grease from the outer CV joint. Place a block of wood, or similar item, between the lower arm and the outer CV joint to prevent the lower arm from striking the outer CV joint.
    NOTE: Once pressure is applied to the ball joint with the special tool, it may be necessary to tap the wheel knuckle at the ball joint area to separate the ball joint from the wheel knuckle.
    NOTE: LH shown, RH similar.
    Fig 16: Identifying Special Tools
    G04680227Courtesy of FORD MOTOR CO.
  23. Using the special tools, separate the lower ball joints from the lower control arms.
    24. NOTE: LH shown, RH similar.
    Fig 17: Locating Lower Control Arms Through Bolt
    G04680228Courtesy of FORD MOTOR CO.
  24. Remove the through bolts from the lower control arms.
  25. Position the special tool under the subframe assembly.
    Fig 18: Locating Special Tool
    G04680229Courtesy of FORD MOTOR CO.
    26. NOTE: LH shown, RH similar.
    Fig 19: Locating Subframe Bracket-To-Body Bolts
    G04680230Courtesy of FORD MOTOR CO.
  26. Remove the subframe bracket-to-body bolts.
    27. NOTE: LH shown, RH similar.
    Fig 20: Locating Rear Subframe Nut
    G04680231Courtesy of FORD MOTOR CO.
  27. Remove the rear subframe nuts and the subframe brackets.
    28. NOTE: LH shown, RH similar.
    Fig 21: Locating Front Subframe Nut
    G04680232Courtesy of FORD MOTOR CO.
  28. Remove the front subframe nuts.
  29. Lower the subframe assembly from the vehicle.
  30. Remove the engine oil pan drain plug and drain the engine oil.
    • Install the drain plug and tighten to 26 Nm (19 lb-ft).
      Fig 22: Locating Drain Plug
      G04680233Courtesy of FORD MOTOR CO.
  31. Remove the oil filter element. For additional information, refer to ENGINE LUBRICATION COMPONENTS - EXPLODED VIEW  and OIL FILTER ELEMENT .
  32. Remove the bolt, 2 nuts and the generator air inlet duct.
    Fig 23: Locating Bolt, Nuts And Generator Air Inlet Duct
    G04680234Courtesy of FORD MOTOR CO.
  33. Remove the engine air cleaner and air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING - 2.3L .
  34. Remove the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  35. Remove the nut and disconnect the wire from the battery cable.
    Fig 24: Locating Battery Cable And Nut
    G04680235Courtesy of FORD MOTOR CO.
  36. Disconnect the 2 engine wiring harness electrical connectors.
    Fig 25: Locating Engine Wiring Harness Electrical Connectors
    G04680236Courtesy of FORD MOTOR CO.
  37. Remove the bolt and the ground wire.
    Fig 26: Locating Bolt And Ground Wire
    G04680237Courtesy of FORD MOTOR CO.
  38. Disconnect the powertrain control module (PCM) electrical connector and pin-type retainer.
    Fig 27: Locating Powertrain Control Module (PCM) Electrical Connector And Pin-Type Retainer
    G04680238Courtesy of FORD MOTOR CO.
  39. Disconnect the fuel supply tube from the fuel rail. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  40. Disconnect the crankcase vent tube from the valve cover.
    Fig 28: Locating Crankcase Vent Tube
    G04680239Courtesy of FORD MOTOR CO.
  41. Depress the locking ring and disconnect the brake booster vacuum supply tube from the intake manifold.
    Fig 29: Locating Locking Ring And Brake Booster Vacuum Supply Tube
    G04680240Courtesy of FORD MOTOR CO.
  42. Disconnect the evaporative emissions (EVAP) tube from the intake manifold.
    Fig 30: Locating Evaporative Emissions (EVAP) Tube
    G04680241Courtesy of FORD MOTOR CO.
  43. Detach the retaining clip and position the EVAP tube bundle aside.
    Fig 31: Locating EVAP Tube Bundle Retaining Clip
    G04680242Courtesy of FORD MOTOR CO.
  44. Disconnect the upper radiator and heater hoses from the coolant bypass.
    Fig 32: Locating Upper Radiator And Heater Hoses
    G04680243Courtesy of FORD MOTOR CO.
  45. If equipped, disconnect the block heater electrical connector and detach the harness retaining clips from the heater hose.
    Fig 33: Locating Harness Retaining Clips
    G04680244Courtesy of FORD MOTOR CO.
  46. Disconnect the heater hose inline connector.
    Fig 34: Locating Heater Hose Inline Connector
    G04680245Courtesy of FORD MOTOR CO.
  47. Remove the 2 clutch tube bracket bolts.
    Fig 35: Locating Clutch Tube Bracket Bolts
    G04680246Courtesy of FORD MOTOR CO.
  48. Remove the 2 bolts and position the clutch slave cylinder aside.
    Fig 36: Locating Clutch Slave Cylinder Bolts
    G04680247Courtesy of FORD MOTOR CO.
  49. Disconnect the transaxle control cables from the control levers.
    • Detach the control cables from the bracket.
      Fig 37: Locating Control Cables
      G04680248Courtesy of FORD MOTOR CO.
  50. Disconnect the power steering cooler tube.
    Fig 38: Locating Power Steering Cooler Tube
    G04680249Courtesy of FORD MOTOR CO.
  51. Remove the bolt and position the radio frequency interference capacitor and ground wire aside.
    Fig 39: Locating Bolt, Radio Frequency Interference Capacitor And Ground Wire
    G04680250Courtesy of FORD MOTOR CO.
  52. Detach the coolant vent hose retaining clip from the A/C tube.
    Fig 40: Locating Coolant Vent Hose Retaining Clip
    G04680251Courtesy of FORD MOTOR CO.
  53. Remove the 2 A/C tube bracket bolts.
    Fig 41: Locating A/C Tube Bracket Bolts
    G04680252Courtesy of FORD MOTOR CO.
  54. Remove the 2 nuts and disconnect the A/C tubes.
    Fig 42: Locating A/C Tubes Nuts
    G04680253Courtesy of FORD MOTOR CO.
  55. Remove the nut and disconnect the A/C tube from the condenser.
    Fig 43: Locating A/C Tube Nut
    G04680254Courtesy of FORD MOTOR CO.
  56. Remove the bolt and the radio frequency interference capacitor from the engine mount bracket.
    Fig 44: Locating Radio Frequency Interference Capacitor And Bolt
    G04680255Courtesy of FORD MOTOR CO.
  57. Remove the retaining clip and disconnect the lower radiator hose.
    Fig 45: Removing Retaining Clip And Locating Lower Radiator Hose
    G04680256Courtesy of FORD MOTOR CO.
  58. Using the special tools, separate the LH halfshaft from the transaxle and support the halfshaft with a length of mechanic's wire.
    Fig 46: Identifying Special Tools
    G04680257Courtesy of FORD MOTOR CO.
  59. Remove the 2 RH halfshaft carrier bearing bracket bolts.
    Fig 47: Locating RH Halfshaft Carrier Bearing Bracket Bolts
    G04680258Courtesy of FORD MOTOR CO.
  60. Separate the RH halfshaft from the transaxle and support the halfshaft with a length of mechanic's wire.
    Fig 48: Locating RH Halfshaft
    G04680259Courtesy of FORD MOTOR CO.
  61. Remove the bellhousing-to-oil pan bolt.
    Fig 49: Locating Bellhousing-To-Oil Pan Bolt
    G04680260Courtesy of FORD MOTOR CO.
  62. Remove the 2 oil pan-to-bellhousing bolts.
    Fig 50: Locating Oil Pan-To-Bellhousing Bolts
    G04680261Courtesy of FORD MOTOR CO.
    63. NOTE: Position a suitable block of wood under the transaxle.
  63. Install the special tools onto the engine.
    • Raise the engine and transaxle 25.4 mm (1 in) to neutralize the engine and transaxle mounts.
      Fig 51: Locating Special Tools
      G04680262Courtesy of FORD MOTOR CO.
  64. Remove the 2 transaxle mount bolts.
    Fig 52: Locating Transaxle Mount Bolts
    G04680263Courtesy of FORD MOTOR CO.
  65. Remove the bolt, 2 nuts and the motor mount bracket.
    Fig 53: Locating Motor Mount Bracket Bolt And Nuts
    G04680264Courtesy of FORD MOTOR CO.
  66. Lower the engine and transaxle from the vehicle.
  67. Remove the 2 nuts and disconnect the starter wires.
    Fig 54: Locating Starter Wires Nuts
    G04680265Courtesy of FORD MOTOR CO.
  68. Detach the 2 wiring harness retainers from the starter stud bolts.
  69. Remove the 2 bolts and the starter.
    Fig 55: Locating Starter Bolts
    G04680266Courtesy of FORD MOTOR CO.
  70. Remove the bolt and ground wire.
    Fig 56: Locating Ground Wire Bolt
    G04680267Courtesy of FORD MOTOR CO.
  71. Remove the nut and position the engine wiring harness bracket aside.
    Fig 57: Locating Engine Wiring Harness Bracket And Nut
    G04680268Courtesy of FORD MOTOR CO.
  72. Disconnect the backup lamp electrical connector.
    Fig 58: Locating Backup Lamp Electrical Connector
    G04680269Courtesy of FORD MOTOR CO.
  73. Disconnect the vehicle speed sensor (VSS) electrical connector.
    Fig 59: Locating Vehicle Speed Sensor (VSS) Electrical Connector
    G04680270Courtesy of FORD MOTOR CO.
  74. Install the special tools and remove the engine and transaxle from the powertrain lift table.
    Fig 60: Identifying Special Tools
    G04680271Courtesy of FORD MOTOR CO.
  75. Remove the bellhousing-to-engine retainers.
    • Separate the engine and transaxle.
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