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Crossmember - Number 2: Removal

WARNING: This page is about a different car, the 2006 Mercury Grand Marquis and 2006 Ford Crown Victoria. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Suspension fasteners are critical parts because they affect the performance of vital components and systems and their failure can result in major repair expense. A new part with the same part number must be installed if installation is necessary. Do not use a new part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts.
  1. Remove the generator. For additional information, refer to GENERATOR AND REGULATOR .
  2. Remove the 3 pin-type retainers and the radiator sight shield.
  3. Install the engine support bar.
    Fig 1: Installing Engine Support Bar
    G04586645Courtesy of FORD MOTOR CO.
  4. Disconnect the RH anti-lock brake system (ABS) electrical connectors.
    Fig 2: Disconnecting RH Anti-Lock Braking System Electrical Connectors
    G04586646Courtesy of FORD MOTOR CO.
  5. Disconnect the LH ABS electrical connectors.
    Fig 3: Disconnecting LH Anti-Lock Braking System Electrical Connectors
    G04586647Courtesy of FORD MOTOR CO.
    6. WARNING: If equipped with fire suppression system, depower the system. For important safety warnings and procedures, refer to FIRE SUPPRESSION SYSTEM .
    WARNING: The electrical power to the air suspension system must be turned off prior to hoisting, jacking or towing an air suspension vehicle. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Failure to follow these instructions may result in personal injury.
  6. Remove the LH and RH front wheel and tire assemblies. For additional information, refer to WHEELS & TIRES .
    7. CAUTION: Do not allow the intermediate shaft to rotate while it is disconnected from the steering gear or damage to the clockspring can result. 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 .
  7. Remove the bolt and detach the intermediate shaft from the steering gear.
  8. Remove the 2 nuts and the 2 bolts from the LH number 2 crossmember bracket and the 2 nuts and the 2 bolts from the RH number 2 crossmember bracket.
    • Separate the number 2 crossmember brackets from the crossmember.
  9. Raise and support the vehicle.
  10. Remove the 2 engine mount nuts.
    11. NOTE: The hex holding feature can be used to prevent turning of the stud while removing the nut.
  11. Remove the 2 nuts and disconnect the LH and RH stabilizer bar links.
    12. NOTE: The hex holding feature can be used to prevent turning of the stud while removing the nut.
  12. Remove the 2 nuts and disconnect the LH and RH outer tie-rod ends.
  13. Remove the 2 bolts and position the LH and RH brake hose and brackets assemblies aside.
    Fig 4: Positioning LH And RH Brake Hose
    G04586648Courtesy of FORD MOTOR CO.
  14. Remove the 4 bolts and position the LH and RH brake calipers aside.
    • Support the brake calipers away from the number 2 crossmember.
  15. Position the front LH and RH ABS harness aside.
    1. Release the 2 ABS harnesses from the support bracket.
    2. Remove the 2 bolts and the brackets.
    3. Remove the 2 harness retainers from the frame.
      Fig 5: Positioning Front LH And RH ABS Harness Aside
      G04586649Courtesy of FORD MOTOR CO.
  16. Remove the 2 steering gear nuts.
  17. Remove the 2 studs and position the steering gear aside.
    • Support the steering gear away from the number 2 crossmember.
      Fig 6: Supporting Steering Gear Away
      G04586650Courtesy of FORD MOTOR CO.
  18. Release the brake line from the retaining clips at the rear of the number 2 crossmember.
    Fig 7: Releasing Brake Line From Retaining Clips
    G04586651Courtesy of FORD MOTOR CO.
  19. Lower the vehicle.
  20. Using the engine support bar, raise the engine to remove the engine weight from the number 2 crossmember.
  21. Raise and support the vehicle.
  22. Remove the 3 LH lower control arm and 3 RH lower control arm rear mounting bolts.
  23. Position a suitable support table under the number 2 crossmember.
  24. Remove the 4 number 2 crossmember bolts.
  25. Lower and remove the number 2 crossmember assembly. Transfer components as necessary.
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