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Transaxle - 3.0L

WARNING: This page is about a different car, the 2006 Mercury Mariner and 2006 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL(S) SPECIFICATION

G04620015Courtesy of FORD MOTOR CO.
 Adapter for 303-290-A (Support Leg)
303-290A-03A
G04620016Courtesy of FORD MOTOR CO.
 Support Bar, Engine
303-290A
G04620017Courtesy of FORD MOTOR CO.
 Adapters for 303-290
303-290A-01
G04620018Courtesy of FORD MOTOR CO.
 Engine Lifting Chains (Part of Spreader Bar)
303-D089 (D93P-6001-A3) or equivalent
G04620019Courtesy of FORD MOTOR CO.
 Retainer, Torque Converter
307-346 (T97T-7902-A)
G04620020Courtesy of FORD MOTOR CO.
 Slide Hammer
100-001 (T50T-100-A)
G04620021Courtesy of FORD MOTOR CO.
 Remover, Halfshaft
205-241 (T86P-3541-A)
G04620022Courtesy of FORD MOTOR CO.
 Tie Rod End Remover
211-105 (T85M-3395-A)

    All vehicles 

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Remove the battery and the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  3. Remove the air cleaner as an assembly.
    1. Disconnect the breather tube.
    2. Disconnect the mass air flow (MAF) sensor electrical connector.
    3. Remove the air intake tube.
    4. Remove the air cleaner assembly retaining bolt.
    5. Remove the air cleaner assembly.
      Fig 1: Identifying Air Cleaner As Assembly
      G04620023Courtesy of FORD MOTOR CO.
  4. Disconnect the transmission range (TR) sensor.
    Fig 2: Locating Transmission Range (TR) Sensor Electrical Connector
    G03897857Courtesy of FORD MOTOR CO.
  5. Disconnect the transaxle harness connector, remove the wire harness bracket nut and position the harness bracket aside.
    Fig 3: Identifying Transaxle Harness Connector
    G04620025Courtesy of FORD MOTOR CO.
  6. Remove the main control cover vent tube.
    Fig 4: Locating Main Control Cover Vent Tube
    G04620026Courtesy of FORD MOTOR CO.

    7. All wheel drive (AWD) vehicles 

  7. Disconnect the EVAP and power transfer unit (PTU) vent hoses from the transmission filler tube.
    Fig 5: Locating Transmission Filler Tube
    G04620027Courtesy of FORD MOTOR CO.

    8. All vehicles 

  8. Disconnect the wire harness from the battery tray hold-down bracket.
    Fig 6: Locating Wire Harness Bracket
    G04620028Courtesy of FORD MOTOR CO.
  9. Disconnect the shift cable from the manual lever.
    Fig 7: Locating Shift Cable From Manual Lever
    G04620029Courtesy of FORD MOTOR CO.
  10. Remove the 2 retaining bolts from the shift cable bracket, and position the cable and bracket aside.
    Fig 8: Locating Shift Cable & Bracket Bolts
    G04620030Courtesy of FORD MOTOR CO.
  11. Disconnect the starter motor harness connector.
    Fig 9: Locating Starter Motor Harness Connector
    G04620031Courtesy of FORD MOTOR CO.
  12. Disconnect the ground wire.
    Fig 10: Locating Ground Wire
    G04620032Courtesy of FORD MOTOR CO.
  13. Remove the 2 starter bolts and remove the starter motor.
    Fig 11: Locating Starter Bolts & Starter Motor
    G04620033Courtesy of FORD MOTOR CO.
  14. Install the special tools.
    Fig 12: Identifying Installation Special Tool
    G04620034Courtesy of FORD MOTOR CO.
  15. Remove and disconnect both electrical connectors from the upper intake to gain access to the engine for installing the lifting bracket.
    Fig 13: Locating Electrical Connectors
    G04620035Courtesy of FORD MOTOR CO.
  16. Install the special tools.
    Fig 14: Identifying Installation Special Tool
    G04620036Courtesy of FORD MOTOR CO.
  17. Install the special tools.
    Fig 15: Identifying Installation Special Tool
    G04620037Courtesy of FORD MOTOR CO.
  18. Remove the upper transaxle retaining bolts.
    Fig 16: Locating Upper Transaxle Retaining Bolts
    G04620038Courtesy of FORD MOTOR CO.
  19. Loosen, but do not remove, the 4 retaining nuts holding the bracket to the transaxle case. Remove the LH upper transaxle mount bolt.
    Fig 17: Locating LH Upper Transaxle Mount Bolt
    G04620039Courtesy of FORD MOTOR CO.
  20. Remove the RH upper engine mount bolt.
    Fig 18: Locating RH Upper Transaxle Mount Bolt
    G04620040Courtesy of FORD MOTOR CO.
  21. Remove the 7 retainers and the LH splash shield.
    Fig 19: View Of LH Splash Shield And Retainers
    G03900504Courtesy of FORD MOTOR CO.
  22. Remove the 7 retainers and the RH splash shield.
    Fig 20: Locating Retainers & RH Splash Shield
    G04620042Courtesy of FORD MOTOR CO.
  23. If transaxle disassembly is necessary, remove the drain plug and drain the transmission fluid. After the fluid has drained, install the drain plug.
    Fig 21: Locating Drain Plug
    G04620043Courtesy of FORD MOTOR CO.
  24. Disconnect the LH suspension.
    1. Disconnect the sway bar link.
    2. Remove the tie rod end nut cotter pin.
    3. Remove the tie rod end retaining nut.
    4. Remove the lower knuckle bolt.
      Fig 22: Identifying LH Suspension
      G04620044Courtesy of FORD MOTOR CO.
  25. Disconnect the RH suspension.
    1. Disconnect the sway bar link.
    2. Remove the tie rod end nut cotter pin.
    3. Remove the tie rod end retaining nut.
    4. Remove the lower control arm knuckle bolt.
      Fig 23: Identifying RH Suspension
      G04620045Courtesy of FORD MOTOR CO.
  26. Using the special tool, disconnect the LH and RH tie rod end from the steering knuckle.
    Fig 24: Removing LH & RH Tie Rod From Steering Knuckle Using Special Tools
    G04620046Courtesy of FORD MOTOR CO.
  27. Carefully pry down on the LH and RH lower control arms and disconnect the steering knuckle from the lower ball joint and position the steering knuckle aside.
  28. Using the special tool, remove the RH outer half shaft.
    Fig 25: Removing RH Outer Halfshaft
    G04620047Courtesy of FORD MOTOR CO.
  29. Using a pry bar between the transaxle case and the LH axle shaft, carefully disconnect the halfshaft from the transaxle case.
  30. Remove the retaining screw for the generator shield.
    Fig 26: Locating Retaining Screw
    G04620048Courtesy of FORD MOTOR CO.
  31. Remove the retaining bolt for the generator shield and remove the shield.
    Fig 27: Locating Retaining Bolt
    G04620049Courtesy of FORD MOTOR CO.
  32. Disconnect the HO2S sensor connector and remove the 2 clips from the oil pan bolt studs.
    Fig 28: Locating HO2S Sensor Connector
    G04620050Courtesy of FORD MOTOR CO.
  33. Remove the 2 intermediate shaft retaining nuts.
    Fig 29: Locating Intermediate Shaft Retaining Nuts
    G04620051Courtesy of FORD MOTOR CO.
  34. Remove the intermediate shaft.
    Fig 30: Locating Intermediate Shaft
    G04620052Courtesy of FORD MOTOR CO.
  35. Remove the cross brace.
    Fig 31: Locating Cross Brace & Bolts
    G03900713Courtesy of FORD MOTOR CO.
  36. Disconnect the exhaust pipe.
    1. Remove the rubber hanger.
    2. Remove the nuts and disconnect the pipe.
      Fig 32: Identifying Exhaust Pipe Nuts
      G04620054Courtesy of FORD MOTOR CO.
  37. Disconnect the front exhaust pipe flange.
    Fig 33: Locating Front Exhaust Pipe Flange
    G04620055Courtesy of FORD MOTOR CO.
  38. Disconnect the rear exhaust pipe flange and remove the exhaust pipe.
    Fig 34: Locating Rear Exhaust Pipe Bolts
    G04620056Courtesy of FORD MOTOR CO.

    39. AWD vehicles 

  39. For vehicles equipped with a PTU, remove the rear driveshaft bolts and separate the driveshaft from the PTU.
    Fig 35: Locating Driveshaft Bolts
    G04620057Courtesy of FORD MOTOR CO.
  40. Position the driveshaft aside.
    Fig 36: Locating Driveshaft
    G04620058Courtesy of FORD MOTOR CO.
  41. Vehicles equipped with a PTU, remove the RH catalytic converter to gain access to the PTU bracket. For additional information, refer to REMOVAL .
  42. Remove the bolts and the bracket.
    Fig 37: Locating Bolts & Bracket
    G04620059Courtesy of FORD MOTOR CO.

    43. All vehicles 

  43. Remove the bolt for the mount and the 2 bolts for the cross brace.
    Fig 38: Identifying Front Roll Restrictor Bolt & Bolts For Engine Support Crossmember
    G04619986Courtesy of FORD MOTOR CO.
  44. Remove and discard the nut and remove the cross brace.
    Fig 39: Identifying Cross Brace And Rear Nut
    G03897887Courtesy of FORD MOTOR CO.
  45. Remove the electrical connectors from the lower mount bracket.
    Fig 40: Locating Electrical Connector From Lower Mount Bracket
    G04620062Courtesy of FORD MOTOR CO.
  46. Remove the bolts from the transfer case unit.
    Fig 41: Locating Transfer Case Unit Bolts
    G04620063Courtesy of FORD MOTOR CO.
  47. Remove the transfer case bolt and remove the transfer case unit.
    Fig 42: Removing Transfer Case Bolt
    G04620064Courtesy of FORD MOTOR CO.
  48. Remove the center bolt from the rear transaxle mount.
    Fig 43: Locating Rear Transaxle Mount Bolts
    G04620065Courtesy of FORD MOTOR CO.
    49. NOTE: It is necessary to raise the engine a couple of inches in order to remove the transaxle.
    Fig 44: Raising Front Of Engine Using Special Tools
    G04620066Courtesy of FORD MOTOR CO.
  49. Using the special tool, raise the front of the engine.
    50. NOTE: It is necessary to lower the transaxle in order to clear the subframe to remove the transaxle.
    Fig 45: Identifying Installation Special Tool
    G04620067Courtesy of FORD MOTOR CO.
  50. Lower the transaxle enough to clear the frame.
  51. Remove the access cover.
    Fig 46: Locating Access Cover
    G04620068Courtesy of FORD MOTOR CO.
  52. Remove and discard the 4 torque converter nuts.
    Fig 47: Locating Torque Converter Nuts
    G04620069Courtesy of FORD MOTOR CO.
  53. Remove the fluid cooler tube.
    1. Disconnect the output shaft speed (OSS) sensor.
    2. Disconnect the turbine shaft speed (TSS) sensor (white connector).
    3. Remove the bolt.
    4. Remove the fluid cooler tube and position it aside.
      Fig 48: Locating Turbine Shaft Speed Sensor Electrical Connector
      G04620070Courtesy of FORD MOTOR CO.
  54. Remove the OSS sensor.
    Fig 49: Locating OSS Sensor Bolt
    G03897862Courtesy of FORD MOTOR CO.
  55. Remove the fluid cooler tube.
    Fig 50: Locating Transmission Fluid Cooler Tube
    G03897859Courtesy of FORD MOTOR CO.
  56. Support the transaxle with a high-lift jack.
  57. Remove the bolts.
    Fig 51: Locating Lower Transaxle Bolts
    G04620073Courtesy of FORD MOTOR CO.
  58. Remove the bolt.
    Fig 52: Locating Transaxle Bolt
    G04620074Courtesy of FORD MOTOR CO.
  59. Remove the bolt.
    Fig 53: Locating Bolt
    G04620075Courtesy of FORD MOTOR CO.
  60. Remove the transaxle mount bracket.
    Fig 54: Locating Transaxle Mount Bracket
    G04620076Courtesy of FORD MOTOR CO.
    61. CAUTION: The torque converter is heavy. Install the special tool before lowering the transaxle.
    Fig 55: Identifying Special Tool
    G03900854Courtesy of FORD MOTOR CO.
  61. Move the transaxle back far enough to install the special tool.
  62. Lower the transaxle from the engine compartment.
    Fig 56: Identifying Transaxle From Engine Compartment
    G04620078Courtesy of FORD MOTOR CO.
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