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Section 658 (Automatic Transaxle/Transmission - FNR5): Removal: Transaxle: Removal

WARNING: This page is about a different car, the 2006 Mercury Milan and 2006 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Remove the air cleaner assembly.
    1. Disconnect the mass air flow (MAF) sensor electrical connector.
    2. Disconnect the engine breather.
    3. Disconnect the brake booster vacuum hose.
    4. Loosen the clamp and remove the air cleaner assembly.
      Fig 1: Identifying Mass Air Flow Sensor Electrical Connector, Engine Breather, Brake Booster Vacuum Hose And Clamp
      G04681859Courtesy of FORD MOTOR CO.
  3. Remove the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  4. Remove the battery tray.
    1. Disconnect the positive battery cable fastener from the battery tray.
    2. Disconnect the 3 wiring harness retainers.
    3. Remove the nut.
    4. Remove the bolt and remove the battery tray.
      Fig 2: Identifying Battery Tray Bolts, Nuts, Wiring Harness Retainers And Positive Battery Cable Fastener
      G04681860Courtesy of FORD MOTOR CO.
  5. Disconnect the selector lever cable end from the manual lever.
    Fig 3: Locating Selector Lever Cable End
    G04681861Courtesy of FORD MOTOR CO.
  6. Remove the 2 bolts, disconnect the harness and position the selector lever cable and bracket aside.
    Fig 4: Locating Selector Lever Cable, Bracket And Bolts
    G04681862Courtesy of FORD MOTOR CO.
  7. Disconnect the transmission range (TR) sensor electrical connector, transmission main valve body electrical connector, and disconnect the harness retainer from the transaxle and position the harness aside.
    Fig 5: Locating Transmission Range (TR) Sensor Electrical Connector, Transmission Main Valve Body Electrical Connector And Harness Retainer
    G04681863Courtesy of FORD MOTOR CO.
  8. Disconnect the turbine shaft speed (TSS) sensor, intermediate shaft speed sensor and 5th gear valve body electrical connector and position the harness aside.
    Fig 6: Locating Turbine Shaft Speed (TSS) Sensor, Intermediate Shaft Speed Sensor And 5Th Gear Valve Body Electrical Connector
    G04681864Courtesy of FORD MOTOR CO.
  9. Remove the ground strap.
    Fig 7: Locating Ground Strap
    G04681865Courtesy of FORD MOTOR CO.
  10. Remove the 3 top bellhousing bolts.
    Fig 8: Locating Top Bellhousing Bolts
    G04681866Courtesy of FORD MOTOR CO.
  11. Remove the 2 roll restrictor bracket bolts.
    Fig 9: Locating Roll Restrictor Bracket Bolts
    G04681867Courtesy of FORD MOTOR CO.
  12. Install the special tool.
    Fig 10: Identifying Special Tool
    G04681868Courtesy of FORD MOTOR CO.
  13. Remove the 2 transaxle insulator bolts and lower the transaxle.
    Fig 11: Locating Transaxle Insulator Bolts
    G04681869Courtesy of FORD MOTOR CO.
  14. Remove the 3 nuts and remove the transaxle insulator bracket.
    Fig 12: Locating Transaxle Insulator Bracket And Nuts
    G04681870Courtesy of FORD MOTOR CO.
  15. Disconnect the pressure switch electrical connector.
    Fig 13: Locating Pressure Switch Electrical Connector
    G04681871Courtesy of FORD MOTOR CO.
  16. Disconnect the output shaft speed (OSS) sensor electrical connector.
    Fig 14: Locating Output Shaft Speed (OSS) Sensor Electrical Connector
    G04681872Courtesy of FORD MOTOR CO.
  17. Remove the 4 screws and position the RH fender splash shield aside.
    Fig 15: Locating RH Fender Splash Shield Screws
    G04681873Courtesy of FORD MOTOR CO.
  18. Remove the 6 pin-type retainers and the RH front structure-to-subframe splash shield.
    Fig 16: Locating RH Front Structure-To-Subframe Splash Shield
    G04681874Courtesy of FORD MOTOR CO.
  19. Remove the 4 screws and position the LH fender splash shield aside.
    Fig 17: Locating LH Fender Splash Shield Screws
    G04681875Courtesy of FORD MOTOR CO.
  20. Remove the 6 pin-type retainers and the LH front structure-to-subframe splash shield.
    Fig 18: Locating LH Front Structure-To-Subframe Splash Shield
    G04681876Courtesy of FORD MOTOR CO.
  21. Remove the LH front power steering bracket bolt.
    Fig 19: Locating LH Front Power Steering Bracket Bolt
    G04681877Courtesy of FORD MOTOR CO.
  22. Remove the 2 LH power steering tube bracket bolts.
    Fig 20: Locating LH Power Steering Tube Bracket Bolts
    G04681878Courtesy of FORD MOTOR CO.
  23. Remove the RH power steering tube bracket bolt.
    Fig 21: Locating RH Power Steering Tube Bracket Bolt
    G04681879Courtesy of FORD MOTOR CO.
    24. NOTE: If installation of a new transmission is necessary, the transmission fluid will need to be drained.
    Fig 22: Locating Transmission Fluid Pan Drain Plug
    G04681880Courtesy of FORD MOTOR CO.
  24. Remove the transmission fluid pan drain plug and allow the fluid to drain.
  25. Install the fluid drain plug.
    • Tighten to 29 Nm (21 lb-ft).
      Fig 23: Locating Transmission Fluid Pan Drain Plug
      G04681881Courtesy of FORD MOTOR CO.
  26. Remove the 2 LH bolts and the RH bolt and position the steering gear aside using mechanic's wire.
    Fig 24: Locating LH Bolts And RH Steering Gear Bolt
    G04681882Courtesy of FORD MOTOR CO.
    27. NOTE: LH shown, RH similar.
    Fig 25: Locating Sway Bar Link Nut
    G04681883Courtesy of FORD MOTOR CO.
  27. Remove the nuts and disconnect the sway bar links from the front struts.
  28. Remove the RH halfshaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
    29. CAUTION: Failure to hold the differential side gears can allow the side gears to rotate and fall out of the differential carrier.
    Fig 26: Locating Differential Side Gear Hole
    G04681884Courtesy of FORD MOTOR CO.
  29. Insert a suitable tool into the RH side of the differential to hold the differential side gears in place.
  30. Remove the LH halfshaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
  31. Support the subframe with a suitable powertrain lift.
  32. Remove the 2 rear subframe nuts.
    Fig 27: Locating Rear Subframe Nuts
    G04681885Courtesy of FORD MOTOR CO.
  33. Remove the 4 bolts and the subframe support brackets.
    Fig 28: Locating Subframe Support Brackets And Bolts
    G04681886Courtesy of FORD MOTOR CO.
    34. NOTE: LH shown, RH similar.
    Fig 29: Locating Front Subframe Nuts
    G04681887Courtesy of FORD MOTOR CO.
  34. Remove front subframe nuts.
  35. Lower the subframe and remove it from the vehicle.
  36. Position the boot aside and remove the starter terminals.
    Fig 30: Locating Starter Terminal Bolts
    G04681888Courtesy of FORD MOTOR CO.
  37. Remove the wiring harness retainer from the starter stud.
    Fig 31: Locating Wiring Harness Retainer
    G04681889Courtesy of FORD MOTOR CO.
  38. Remove the 2 stud bolts and the starter.
    Fig 32: Locating Starter Bolts
    G04681890Courtesy of FORD MOTOR CO.
  39. Disconnect the transmission fluid cooler hoses from the transmission.
    Fig 33: Locating Transmission Fluid Cooler Hoses
    G04681891Courtesy of FORD MOTOR CO.
    40. CAUTION: Only rotate the engine in a clockwise direction or engine damage will occur.
    NOTE: Mark one stud and the flexplate for assembly reference.
    Fig 34: Locating Torque Converter Nuts
    G04681892Courtesy of FORD MOTOR CO.
  40. Remove and discard the 4 torque converter nuts.
  41. Remove the nut and the bracket from the torque converter housing stud bolt.
    Fig 35: Locating Torque Converter Housing Stud Bolt
    G04681893Courtesy of FORD MOTOR CO.
  42. Support the transaxle with a suitable transmission jack.
  43. Remove the 3 back torque converter housing bolts.
    Fig 36: Locating Back Torque Converter Housing Bolts
    G04681894Courtesy of FORD MOTOR CO.
  44. Remove the 3 front torque converter housing bolts.
    Fig 37: Locating Front Torque Converter Housing Bolts
    G04681895Courtesy of FORD MOTOR CO.
  45. Separate the transaxle from the engine and install the special tool.
    Fig 38: Identifying Special Tool
    G04681896Courtesy of FORD MOTOR CO.
  46. Remove the transaxle from the vehicle.
  47. If installing a new transaxle, the fluid cooler will need to be backflushed and cleaned. Carry out transmission fluid cooler tube backflushing and cleaning. For additional information, refer to TRANSMISSION FLUID COOLER - BACKFLUSHING AND CLEANING .
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