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Home >> Ford >> 2009 >> Flex Limited, FWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1629 (Instrument Panel & Console) >> Removal And Installation >> In-Vehicle Crossbeam >> Removal

In-Vehicle Crossbeam: Removal

WARNING: This page is about a different car, the 2009 Mercury Sable, 2009 Ford Taurus X, and 2009 Ford Taurus. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the instrument panel upper section. For additional information, refer to Instrument Panel Upper Section .
  2. Recover the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS article.
  3. Drain the cooling system. For additional information, refer to ENGINE COOLING article.
  4. Remove the wiper mounting arm and pivot shaft assembly. For additional information, refer to WIPERS AND WASHERS article.
  5. Remove the 2 nuts and the PCM.
    • Disconnect the 3 PCM electrical connectors.
    6. Fig 1: Identifying Nuts
    GF0045464Courtesy of FORD MOTOR CO.
  6. Remove the 3 nuts and the PCM bracket.
    7. Fig 2: Identifying Nuts
    GF0045465Courtesy of FORD MOTOR CO.
  7. Remove the strut tower cross brace.
    • Remove the 2 LH and 2 RH strut upper mount nuts.
    8. Fig 3: Identifying Nuts
    GF0045467Courtesy of FORD MOTOR CO.
  8. Remove the RH instrument panel upper cowl bolt.
    9. Fig 4: Identifying Bolt
    GF0016562Courtesy of FORD MOTOR CO.
  9. Remove the 2 LH instrument panel upper cowl bolts.
    10. Fig 5: Identifying Bolts
    GF0016563Courtesy of FORD MOTOR CO.
  10. Disconnect the vacuum hose and the evaporator purge solenoid hose from the upper intake manifold.
    11. Fig 6: Identifying Vacuum Hose And Evaporator Purge Solenoid Hose
    GF0045476Courtesy of FORD MOTOR CO.
  11. Remove the thermostatic expansion valve (TXV) manifold.
    • Remove the TXV manifold bolt.
    • Discard the O-ring seals.
    12. Fig 7: Identifying Bolt And O-Rings
    GF0016561Courtesy of FORD MOTOR CO.
  12. Disconnect the heater hoses.
    13. Fig 8: Identifying Heater Hoses
    GF0016560Courtesy of FORD MOTOR CO.
  13. Remove the RH and LH front door weatherstrips.
  14. Rotate the steering wheel to gain access to the steering column shaft-to-steering column bolt.
  15. Remove and discard the steering column shaft-to-steering column bolt.
    16. Fig 9: Removing Steering Column Pinch Bolt
    GF0016574Courtesy of FORD MOTOR CO.
  16. Rotate the steering wheel until the front wheels are in the straight-ahead position.
    • Remove the ignition key.
    17. NOTE: Do not allow the steering column shaft to rotate while the intermediate shaft is disconnected or damage to the clockspring may result. If there is evidence that the shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to SUPPLEMENTAL RESTRAINT SYSTEM article.
  17. Detach the upper steering column shaft from the steering column.
  18. Disconnect the LH side main wiring harness electrical connector.
    19. Fig 10: Disconnecting LH Side Main Wiring Harness Electrical Connectors
    GF0016575Courtesy of FORD MOTOR CO.
  19. Disconnect the 2 smart junction box (SJB) electrical connectors.
    20. Fig 11: Identifying SJB Connectors
    GF0045471Courtesy of FORD MOTOR CO.
  20. Remove the wire harness pin-type retainer from the SJB.
  21. If equipped, disconnect the electrical connector located on the steering column opening bracket.
    22. Fig 12: Identifying Connector
    GF0045472Courtesy of FORD MOTOR CO.
  22. Disconnect the restraints control module (RCM) small electrical connector.
    23. Fig 13: Disconnecting Restraints Control Module (RCM) Small Electrical Connector
    GF0016576Courtesy of FORD MOTOR CO.
  23. Disconnect the stability control sensor cluster electrical connector.
    24. Fig 14: Identifying Connector
    GF0045473Courtesy of FORD MOTOR CO.
  24. Remove the 4 instrument panel center support bolts.
    25. NOTE: To avoid damaging the front door trim panel, an assistant is required when carrying out this step.
    NOTE: Remove the instrument panel side bolts from one side completely and support the in-vehicle crossbeam before removing the instrument panel side bolts from the opposite side.
    NOTE: Make sure that all electrical connectors and wiring are not hindered before removing the in-vehicle crossbeam.
  25. Remove the in-vehicle crossbeam.
    • Remove the 6 instrument panel side bolts.
    • Transfer parts as needed.
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