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Section 16 (Manual Transaxle): Removal: Transaxle: Removal

WARNING: This page is about a different variant/trim than selected.
WARNING: Do not breathe dust or use compressed air to blow dust from storage containers or friction components. Remove dust using government-approved techniques. Friction component dust may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure to follow these instructions may result in serious personal injury.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING article.
  2. Remove the Air Cleaner (ACL) assembly. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - 2.5L article.
  3. Remove the battery tray. For additional information, refer to BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES article.
  4. Remove the wiring harness bracket nut.
    Fig 1: Locating Wiring Harness Bracket Nut
    G06098207Courtesy of FORD MOTOR CO.
  5. Disconnect the reverse switch and Vehicle Speed Sensor (VSS) connectors. Detach the VSS  pushpin retainers from the shift cable bracket.
    Fig 2: Locating Reverse Switch And Vehicle Speed Sensor (VSS) Connectors
    G06098208Courtesy of FORD MOTOR CO.
  6. Disconnect the shift cables.
    Fig 3: Locating Shift Cables
    G06098209Courtesy of FORD MOTOR CO.
  7. Remove the 3 shift cable bracket bolts. Position the bracket and shift cables aside.
    Fig 4: Locating Shift Cable Bracket Bolts
    G06098210Courtesy of FORD MOTOR CO.
    8. NOTE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.
    Fig 5: Identifying Clutch Hydraulic Tube And Bracket
    G06095098Courtesy of FORD MOTOR CO.
  8. Position the clutch hydraulic tube aside.
    1. Remove the clutch hydraulic tube bracket-to-transaxle bolt.
    2. Disconnect the clutch hydraulic tube from the clutch slave cylinder.
      • Plug the hydraulic tube.
    3. Position the clutch hydraulic tube aside.
  9. Using the Engine Support Bar and Adapters, support the engine.
    Fig 6: Supporting Engine Using Engine Support Bar And Adapters
    G06097263Courtesy of FORD MOTOR CO.
  10. Remove the 3 LH transaxle support insulator bracket nuts. Loosen, but do not remove the through bolt.
  11. Remove the transaxle rear support insulator bolt and the 2 nuts.
  12. Remove the RH engine mount bolt.
  13. Remove the 3 upper transaxle-to-engine bolts.
    Fig 7: Remove/Install Upper Transaxle-To-Engine Bolts
    G06098213Courtesy of FORD MOTOR CO.
    NOTE: Do not use heat to loosen a seized wheel nut or damage to the wheel and wheel bearing can occur.
  14. Remove the wheel and tire. For additional information, refer to TIRES & WHEELS article.
  15. Remove the 6 LH splash shield screws.
    Fig 8: Locating LH Splash Shield Screws
    G06098214Courtesy of FORD MOTOR CO.
  16. Remove the LH lower splash shield.
    1. Remove the 6 screws and a pushpin.
    2. Remove the LH splash shield.
    Fig 9: Identifying LH Lower Splash Shield
    G06098215Courtesy of FORD MOTOR CO.
  17. Remove the crossmember.
    1. Remove the bolts.
    2. Remove the crossmember.
    Fig 10: Identifying Crossmember Bolts
    G06098216Courtesy of FORD MOTOR CO.
  18. Remove the 3 front-to-aft crossmember bolts.
  19. Remove the transaxle front support insulator through bolt.
  20. Remove the front-to-aft crossmember and the transaxle front support insulator.
  21. Remove the transaxle right support insulator through bolt and the mount.
  22. Remove the starter motor assembly. For additional information, refer to STARTING SYSTEM article.
  23. Disconnect the LH stabilizer bar link.
  24. Using the Ball Joint Separator, disconnect the LH tie-rod end.
    Fig 11: Disconnecting Tie-Rod End Using Ball Joint Separator
    G06094636Courtesy of FORD MOTOR CO.
  25. Separate the LH lower ball joint from the wheel knuckle.
    1. Remove the pinch bolt and nut.
    2. Separate the lower ball joint from the wheel knuckle.
    Fig 12: Identifying Pinch Bolt And Nut
    G06098218Courtesy of FORD MOTOR CO.
  26. Remove the clip, then disconnect the brake hose.
  27. Remove the bolt and position the ABS wire aside.
  28. Using the Slide Hammer with the Halfshaft (Plate) Remover, remove the LH front drive halfshaft from the differential.
    • Support the halfshaft with a length of mechanic's wire.
    Fig 13: Removing LH Front Drive Halfshaft From Differential
    G06094410Courtesy of FORD MOTOR CO.
  29. Disconnect the RH stabilizer bar link.
  30. Using the Ball Joint Separator, disconnect the RH tie-rod end.
    Fig 14: Disconnecting Tie-Rod End Using Ball Joint Separator
    G06094636Courtesy of FORD MOTOR CO.
  31. Separate the RH lower ball joint from the wheel knuckle.
    1. Remove the pinch bolt and nut.
    2. Separate the lower ball joint from the wheel knuckle.
    Fig 15: Identifying Pinch Bolt And Nut
    G06098218Courtesy of FORD MOTOR CO.
  32. Remove the clip, then disconnect the brake hose.
  33. Remove the bolt and position the ABS wire aside.
  34. Using a brass drift to strike the RH halfshaft in the indicated area, separate and remove the halfshaft from the intermediate shaft.
    • Support the halfshaft with a length of mechanic's wire.
    Fig 16: Locating Halfshaft From Intermediate Shaft
    G06094411Courtesy of FORD MOTOR CO.
  35. Remove the 2 intermediate shaft retaining nuts.
    • Remove the heat shield and intermediate shaft.
    Fig 17: Locating Intermediate Shaft Retaining Nuts
    G06393949Courtesy of FORD MOTOR CO.
  36. Working in the engine compartment, use the Engine Support Bar to raise the engine up 25.4 mm (1.0 in), lowering the transaxle side downward.
  37. Remove 2 lower transaxle-to-engine bolts.
    38. WARNING: Secure the assembly to the jack. Avoid any obstructions while lowering and raising the jack. Contact with obstructions may cause the assembly to fall off the jack, which may result in serious personal injury.
  38. Position the transmission jack under the transaxle.
  39. Remove the remaining 4 transaxle-to-engine bolts.
  40. Remove the transaxle.
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