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In-Vehicle Crossbeam: Removal

  1. Rotate the steering wheel until the front wheels are in the straight-ahead position.
  2. Drain the coolant. For additional information, refer to ENGINE COOLING .
  3. Recover the refrigerant. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .
  4. Remove the wiper mounting arm and pivot shaft assembly. For additional information, refer to WIPERS AND WASHERS .
  5. Disconnect the 3 PCM electrical connectors.
  6. Remove the wire harness retainer from the PCM bracket stud.
    Fig 1: Locating Wire Harness Retainer Of PCM Bracket Stud
    G06071020Courtesy of FORD MOTOR CO.
  7. Remove the 2 nuts and the PCM.
    Fig 2: Locating Nuts And PCM
    G06071051Courtesy of FORD MOTOR CO.
  8. Remove the 3 nuts and the PCM bracket.
    Fig 3: Locating Nuts And PCM Bracket
    G06071022Courtesy of FORD MOTOR CO.
  9. Remove the vacuum hose clip from the strut tower cross brace.
    Fig 4: Locating Vacuum Hose Clip
    G06071023Courtesy of FORD MOTOR CO.
  10. NOTE: LH side shown in illustration, RH side similar.

    Remove the strut tower cross brace.

    • Remove the LH and RH strut upper mount inboard nuts.
    Fig 5: Locating Strut Upper Mount Inboard Nuts
    G06071024Courtesy of FORD MOTOR CO.
  11. Remove the vacuum hose and the evaporator purge solenoid hose from the upper intake manifold and position aside.
    Fig 6: Locating Vacuum Hose And Evaporator Purge Solenoid Hose
    G06071080Courtesy of FORD MOTOR CO.
  12. Remove the crankcase vent tube and the vacuum tube from the Air Cleaner (ACL) outlet pipe.
    Fig 7: Locating Crankcase Vent Tube And Vacuum Tube
    G06071026Courtesy of FORD MOTOR CO.
  13. Loosen the ACL  outlet pipe-to-Throttle Body (TB) clamp and the ACL  outlet pipe-to-air cleaner cover clamp.
    Fig 8: Locating ACL Outlet Pipe-To-Throttle Body Clamp And ACL Outlet Pipe-To-Air Cleaner Cover Clamp
    G06071027Courtesy of FORD MOTOR CO.
  14. Remove the ACL  outlet pipe.
  15. Remove the heater hoses from the heater hose separator.
    Fig 9: Locating Heater Hoses
    G06071056Courtesy of FORD MOTOR CO.
  16. Remove the heater hoses from the heater hose tubes and position aside.
    Fig 10: Locating Heater Hoses
    G06071029Courtesy of FORD MOTOR CO.
  17. Remove the heater hoses from the heater core and position aside.
    Fig 11: Locating Heater Hoses
    G06071030Courtesy of FORD MOTOR CO.
  18. Remove the Thermostatic Expansion Valve (TXV) manifold bolt and the TXV  manifold.
    • Discard the O-ring seals.
    Fig 12: Locating Thermostatic Expansion Valve Manifold Bolt And TXV Manifold
    G06071031Courtesy of FORD MOTOR CO.
  19. Remove the RH and LH instrument panel upper cowl bolts.
  20. Remove the front seats. For additional information, refer to SEATING .
  21. Remove the instrument panel upper section. For additional information, refer to INSTRUMENT PANEL UPPER SECTION .
  22. Disconnect the LH instrument panel bulkhead electrical connector.
    Fig 13: Locating LH Instrument Panel Bulkhead Electrical Connector
    G06071033Courtesy of FORD MOTOR CO.
  23. Disconnect the 2 Smart Junction Box (SJB) lower electrical connectors and the lower bulkhead electrical connector.
    Fig 14: Locating Smart Junction Box Lower Electrical Connectors And Lower Bulkhead Electrical Connector
    G06071034Courtesy of FORD MOTOR CO.
  24. Remove and discard the steering column shaft-to-steering column bolt.
    Fig 15: Locating Steering Column Shaft-To-Steering Column Bolt
    G06071046Courtesy of FORD MOTOR CO.
  25. Detach the steering column shaft from the steering column.
  26. Remove the driver footrest pad.
    • Remove the 2 pin-type retainers.
    Fig 16: Locating Pin-Type Retainers And Driver Footrest Pad
    G06071036Courtesy of FORD MOTOR CO.
  27. NOTE: To avoid damaging the carpet with coolant when the instrument panel is removed, the carpet must be removed.

    Remove the LH and RH front carpet sections.

    • Remove the 2 pin-type retainers.
  28. If equipped, remove the 2 pin-type retainers and the rear footwell duct.
    Fig 17: Locating Pin-Type Retainers And Rear Footwell Duct
    G06071037Courtesy of FORD MOTOR CO.
  29. Disconnect the RH bulkhead electrical connector, antenna cable and if equipped, the satellite radio antenna connector.
    Fig 18: Locating RH Bulkhead Electrical Connector, Antenna Cable And Satellite Radio Antenna Connector
    G06071038Courtesy of FORD MOTOR CO.
  30. Remove the 2 bolts and the ground wires.
    Fig 19: Locating Bolts And Ground Wires
    G06071039Courtesy of FORD MOTOR CO.
  31. Disconnect the Restraints Control Module (RCM) small electrical connector and detach the 2 wire harness pin-type retainers.
    Fig 20: Locating Restraints Control Module Small Electrical Connector And Detach 2 Wire Harness Pin-Type Retainers
    G06071040Courtesy of FORD MOTOR CO.
  32. Remove the 4 instrument panel center support bracket bolts.
  33. NOTE: An assistant is required when carrying out this step.
    NOTE: Remove the bolts from one side of the in-vehicle cross beam and support the in-vehicle cross beam before removing the bolts from the opposite side.

    Remove the 3 LH and 3 RH instrument panel side bolts.

  34. NOTE: To avoid damaging the RH front door trim panel when removing the in-vehicle cross beam from the vehicle, an assistant is required when carrying out this step.
NOTE: Make sure that all electrical connectors and wiring are not hindered before removing the in-vehicle cross beam.

Remove the in-vehicle cross beam from the vehicle.

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