Special Tool(s)

WARNING: This page is about a different variant/trim than selected.

SPECIAL TOOLS DESCRIPTION

	Disconnect Tool, Transmission Cooler Line 307-569
	2,200# Floor Crane, Fold Away 300-OTC1819E or equivalent
	Powertrain Lift 014-00765 or equivalent
	Remover, Halfshaft Oil Seal 308-428
	Slide Hammer 100-001 (T50T-100-A)
	Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
	Adjustable Grip Arm, 1735A 014-00001 or equivalent

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

All vehicles

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING article.
Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
Remove the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - 2.5L article.
Remove the battery tray. For additional information, refer to BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES article.
Drain the engine oil.
- Install the drain plug.
- To install, tighten to 28 Nm (21 lb-ft).
Remove the RH and LH halfshafts. For additional information, refer to FRONT DRIVE HALFSHAFTS article.
Drain the cooling system. For additional information, refer to ENGINE COOLING article.
Remove the bolts and the lateral support crossmember.

Fig 1: Locating Lateral Support Crossmember Bolts
Courtesy of FORD MOTOR CO.
Remove the exhaust downpipe and exhaust intermediate pipe. For additional information, refer to EXHAUST SYSTEM article.
Remove the 2 intermediate shaft bearing retainer nuts.

Fig 2: Locating Intermediate Shaft Bearing Retainer Nuts
Courtesy of FORD MOTOR CO.

NOTE: On All-Wheel Drive (AWD) vehicles, the Power Transfer Unit (PTU) seal must be replaced every time the intermediate shaft is removed.

Fig 3: Locating Intermediate Shaft

Courtesy of FORD MOTOR CO.

Remove the intermediate shaft.
Remove the accessory drive belt. For additional information, refer to ACCESSORY DRIVE - 2.5L article.
Press the locking tab to release the generator air duct and remove.

Fig 4: Locating Locking Tab And Generator Air Duct
Courtesy of FORD MOTOR CO.
Remove the drain plug and drain the transmission fluid. For additional information, refer to AUTOMATIC TRANSAXLE/TRANSMISSION - 6F35 article.
All-Wheel Drive (AWD) vehicles
Drain the PTU . For additional information, refer to TRANSFER CASE - POWER TRANSFER UNIT (PTU) article.
Index-mark the driveshaft to the yoke and remove the 6 bolts holding the driveshaft to the PTU and position aside with mechanic's wire.

Fig 5: Locating Driveshaft Bolts
Courtesy of FORD MOTOR CO.

All vehicles
If equipped, remove the bolt and ground eyelet.

Fig 6: Locating Ground Eyelet Bolts
Courtesy of FORD MOTOR CO.
Disconnect the transaxle electrical connector.

Fig 7: Locating Transaxle Electrical Connector
Courtesy of FORD MOTOR CO.
Detach the wiring harness retainer from the transaxle stud bolt.

Fig 8: Locating Wiring Harness Retainer Of Transaxle Stud Bolt
Courtesy of FORD MOTOR CO.
Disconnect the Turbine Shaft Speed (TSS) sensor electrical connector.

Fig 9: Locating Turbine Shaft Speed (TSS) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the 2 secondary latches from the transaxle fluid cooler tubes.

Fig 10: Locating Secondary Latches Of Transaxle Fluid Cooler Tubes
Courtesy of FORD MOTOR CO.
Using the Transmission Cooler Line Disconnect Tool, disconnect the 2 transaxle fluid cooler tubes (1 shown in illustration).

Fig 11: Disconnecting Transaxle Fluid Cooler Tubes
Courtesy of FORD MOTOR CO.
Remove the Power Distribution Box (PDB) cover.

Fig 12: Locating Power Distribution Box (PDB) Cover
Courtesy of FORD MOTOR CO.
Remove the nut and disconnect the cable from the PDB .

Fig 13: Locating PDB Cable Nut
Courtesy of FORD MOTOR CO.
Disconnect the electrical connector from the PDB .

Fig 14: Locating PDB Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the bolt and the ground strap.

Fig 15: Locating Ground Strap Bolt
Courtesy of FORD MOTOR CO.
Detach the 2 wiring harness retainers from the battery tray bracket and position the wiring harness aside.

Fig 16: Locating Battery Tray Bracket Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
Disconnect the shift cable from the transaxle manual lever.

Fig 17: View Of Shift Cable Of Transaxle Manual Lever
Courtesy of FORD MOTOR CO.
Pinch the 2 tabs and remove the transmission shift cable from the bracket.

Fig 18: View Of Transmission Shift Cable Tabs
Courtesy of FORD MOTOR CO.
Detach the shift cable pin-type retainer and position the shift cable aside.

Fig 19: Locating Shift Cable Pin-Type Retainer
Courtesy of FORD MOTOR CO.
If equipped, disconnect the block heater electrical connector. Detach all the block heater wiring harness retainers and position the wiring harness aside.

Fig 20: Locating Block Heater Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the upper radiator hose.

Fig 21: Locating Upper Radiator Hose
Courtesy of FORD MOTOR CO.
Detach the heater hose support strap from the stud.

Fig 22: Locating Heater Hose Support Strap Of Stud
Courtesy of FORD MOTOR CO.
Disconnect the heater hoses from the heater core.

Fig 23: Locating Heater Hoses Of Heater Core
Courtesy of FORD MOTOR CO.
Disconnect the vacuum supply tube and position aside.

Fig 24: Locating Vacuum Supply Tube
Courtesy of FORD MOTOR CO.
Disconnect the fuel vapor return tube.
- Detach the fuel vapor tube retainer from the wire harness.
Fig 25: Locating Fuel Vapor Return Tube
Courtesy of FORD MOTOR CO.
Disconnect the fuel supply tube quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.

Fig 26: Locating Fuel Supply Tube Quick Connect Coupling
Courtesy of FORD MOTOR CO.
Disconnect the PCM electrical connector and the wire harness retainer.

Fig 27: Locating PCM Electrical Connector And Wire Harness Retainer
Courtesy of FORD MOTOR CO.
Disconnect the engine control harness electrical connector.

Fig 28: Locating Engine Control Harness Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the generator electrical connector and the 2 retainers.

Fig 29: Locating Generator Electrical Connector And Retainers
Courtesy of FORD MOTOR CO.
Disconnect the A/C compressor electrical connector and remove the 3 bolts. Position the A/C compressor aside and support the compressor with a length of mechanic's wire.
- Detach the wire harness retainer.
Fig 30: Locating A/C Compressor Electrical Connector And Bolts
Courtesy of FORD MOTOR CO.
Disconnect the lower radiator hose from the radiator.

Fig 31: Locating Lower Radiator Hose
Courtesy of FORD MOTOR CO.
Remove the front roll restrictor bolt and the 2 bolts for the engine support crossmember.

Fig 32: Locating Front Roll Restrictor And Engine Support Crossmember Bolts
Courtesy of FORD MOTOR CO.
Remove the rear nut and the engine support crossmember.
- Discard the nut.
Fig 33: Locating Engine Support Crossmember Rear Nut
Courtesy of FORD MOTOR CO.
If equipped, remove the 3 bolts and the dampener.

Fig 34: Locating Dampener And Bolts
Courtesy of FORD MOTOR CO.

NOTE: The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.

Fig 35: Locating Transaxle-To-Engine Bolts

Courtesy of FORD MOTOR CO.

Remove the 2 transaxle-to-engine bolts.

NOTE: The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.

Fig 36: Locating Transaxle-To-Engine Bolts

Courtesy of FORD MOTOR CO.

Remove the 2 transaxle-to-engine bolts.
AWD vehicles
Remove the 4 PTU bracket-to-engine bolts.

Fig 37: Locating PTU Bracket-To-Engine Bolts

Courtesy of FORD MOTOR CO.

Remove the PTU bracket-to-engine bolt.

Fig 38: Locating PTU Bracket-To-Engine Bolt
Courtesy of FORD MOTOR CO.
Remove the 2 PTU bracket-to-PTU bolts and remove the bracket.

Fig 39: Locating PTU Bracket-To-PTU Bolts And Bracket
Courtesy of FORD MOTOR CO.

All vehicles
Remove the spin-on engine oil filter.

Fig 40: Locating Engine Oil Filter
Courtesy of FORD MOTOR CO.
Using the Powertrain Lift and Adjustable Grip Arm, secure the engine to the lift table.

Fig 41: Securing Engine And Transaxle Onto Powertrain Lift
Courtesy of FORD MOTOR CO.
Remove the engine mount bracket bolt.

Fig 42: Locating Engine Mount Bracket Bolt
Courtesy of FORD MOTOR CO.
Remove the 3 nuts and the engine mount bracket.

Fig 43: Locating Engine Mount Bracket Nuts
Courtesy of FORD MOTOR CO.

NOTE: Late build AWD vehicle equipped with a mass damper shown in illustration, other vehicles similar.

Fig 44: View Of Transaxle Rear Mount Bolt

Courtesy of FORD MOTOR CO.

Remove the bolt from the transaxle rear mount and the mass damper (if equipped).
Remove the bolt from the LH transaxle mount.

Fig 45: Locating LH Transaxle Mount Bolt
Courtesy of FORD MOTOR CO.
Lower the engine and transaxle from the vehicle.
Disconnect the starter terminals.
1. Remove the battery cable nut.
2. Remove the starter solenoid terminal nut.
Fig 46: Identifying Battery Cable And Starter Solenoid Terminal Nuts
Courtesy of FORD MOTOR CO.
Remove the nut and the ground wire.

Fig 47: Locating Ground Wire Nut
Courtesy of FORD MOTOR CO.
Remove the 2 stud bolts and remove the starter.

Fig 48: Locating Starter Motor Stud Bolts
Courtesy of FORD MOTOR CO.
Remove the starter motor isolator.

Fig 49: Locating Starter Motor Isolator
Courtesy of FORD MOTOR CO.

AWD vehicles
Detach the PTU vent hose retainer.

Fig 50: Locating PTU Vent Hose Retainer
Courtesy of FORD MOTOR CO.
Remove the LH lower PTU bolt.

Fig 51: Locating LH Lower PTU Bolt
Courtesy of FORD MOTOR CO.
Remove the 3 RH PTU bolts and the PTU .

Fig 52: Locating PTU And RH PTU Bolts
Courtesy of FORD MOTOR CO.
Remove the 3 bolts and the PTU heat shield.

Fig 53: Locating PTU Heat Shield Bolts
Courtesy of FORD MOTOR CO.
Using the Halfshaft Oil Seal Remover and Slide Hammer, remove the intermediate shaft seal.

Fig 54: Removing Intermediate Shaft Seal
Courtesy of FORD MOTOR CO.

All vehicles
Remove and discard the 4 torque converter nuts.

Fig 55: Locating Torque Converter Nut
Courtesy of FORD MOTOR CO.
Using the Floor Crane and Spreader Bar, remove the engine and transaxle from the lift table.

NOTE: The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.

Remove the remaining 6 engine-to-transaxle bolts and separate the engine and transaxle.