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In-Vehicle Crossbeam: Removal

WARNING: This page is about a different car, the 2005 Mercury Montego, 2005 Ford Freestyle, and 2005 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.

    All vehicles 

  1. Remove the instrument panel upper section. For additional information, refer to INSTRUMENT PANEL UPPER SECTION .
  2. Evacuate and recover the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
  3. Disconnect the heater hoses.
    Fig 1: Disconnecting Heater Hoses
    G03989187Courtesy of FORD MOTOR CO.
  4. Remove the thermostatic expansion valve (TXV) manifold bolt.
    • Discard the O-ring seals.
  5. Remove the powertrain control module (PCM), for additional information, refer to ELECTRONIC ENGINE CONTROLS .
  6. Remove the transaxle roll restrictor bolt.
    Fig 2: Locating Upper Roll Restrictor Bolt
    G03989188Courtesy of FORD MOTOR CO.
    7. NOTE: LH side shown; RH side similar.
    Fig 3: Identifying Transaxle Roll Restrictor Bar Bolts
    G03989189Courtesy of FORD MOTOR CO.
  7. Remove the transaxle roll restrictor bar bolts.
  8. Remove the LH instrument panel cowl top bolt.
    Fig 4: Removing LH Instrument Panel Cowl Top Bolt
    G03989190Courtesy of FORD MOTOR CO.
  9. Remove the 2 RH instrument panel cowl top bolts.
    Fig 5: Removing RH Instrument Panel Cowl Top Bolts
    G03989191Courtesy of FORD MOTOR CO.
    10. NOTE: Freestyle shown; Five Hundred, Montego similar.
    Fig 6: Removing Steering Column Pinch Bolt
    G03989192Courtesy of FORD MOTOR CO.
  10. Remove the steering column pinch bolt.

    11. Freestyle 

  11. Remove the A/C floor duct.
    Fig 7: Removing A/C Floor Duct
    G03989193Courtesy of FORD MOTOR CO.

    12. All vehicles 

  12. Remove the 4 tunnel brace bolts.
  13. Disconnect the small restraints control module (RCM) electrical connector.
  14. Disconnect the large RCM electrical connector.
    1. Pinch the thumb tab and pivot the connector position assurance lever all the way back until it stops.
    2. Pull out and disconnect the large RCM electrical connector.
      Fig 8: Disconnecting Large RCM Electrical Connector
      G03989194Courtesy of FORD MOTOR CO.
    15. CAUTION: To avoid injury or damage to the crossbeam, the help of an assistant is required to carry out this step.
    NOTE: Mark the location of the crossbeam bolts for proper alignment upon installation.
    NOTE: Remove the bolts from one side completely and support the crossbeam before removing bolts from the other side.
  15. Remove the crossbeam.
    • Remove the tunnel reinforcement bolts.
  16. If installing a new in-vehicle crossbeam, remove the heater core and evaporator core housing. For additional information, refer to HEATING & VENTILATION .
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