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In-Vehicle Crossbeam: Removal

  1. Rotate the steering wheel until the front wheels are in the straight-ahead position.
  2. Drain the coolant. For additional information, refer to ENGINE COOLING SYSTEM .
  3. Recover the refrigerant. For additional information, refer to HVAC - CLIMATE CONTROL SYSTEM - GENERAL INFORMATION & DIAGNOSTICS .
  4. Remove the wiper mounting arm and pivot shaft assembly. For additional information, refer to WIPER SYSTEM & WASHER SYSTEM .
  5. Disconnect the 3 PCM electrical connectors.
  6. Remove the wire harness retainer from the PCM bracket stud.
    Fig 1: Locating PCM Bracket Stud
    G07466805Courtesy of FORD MOTOR CO.
  7. Remove the 2 nuts and the PCM.
    Fig 2: Locating PCM Nuts
    G07466806Courtesy of FORD MOTOR CO.
  8. Remove the 3 nuts and the PCM bracket.
    Fig 3: Locating PCM Bracket Nuts
    G07466807Courtesy of FORD MOTOR CO.
  9. Remove the vacuum hose clip from the strut tower cross brace.
    Fig 4: Locating Vacuum Hose Clip
    G07466808Courtesy of FORD MOTOR CO.
    10. NOTE: LH side shown in the illustration, RH side similar.
  10. Remove the strut tower cross brace.
    • Remove the LH and RH strut upper mount inboard nuts.
      Fig 5: Locating LH And RH Strut Upper Mount Inboard Nuts
      G07466809Courtesy of FORD MOTOR CO.
  11. Remove the vacuum hose and the evaporator purge solenoid hose from the upper intake manifold and position aside.
    Fig 6: Locating Vacuum Hose And Evaporator Purge Solenoid Hose
    G07466810Courtesy of FORD MOTOR CO.
  12. Remove the crankcase vent tube and the vacuum tube from the Air Cleaner (ACL) outlet pipe.
    Fig 7: Locating Crankcase Vent And Vacuum Tubes
    G07466811Courtesy of FORD MOTOR CO.
  13. Loosen the ACL  outlet pipe-to-Throttle Body (TB) clamp and the ACL  outlet pipe-to- ACL  cover clamp.
    Fig 8: Locating ACL Outlet Pipe-To-Throttle Body (TB) And ACL Outlet Pipe-To-ACL Cover Clamps
    G07466812Courtesy of FORD MOTOR CO.
  14. Remove the ACL  outlet pipe.
  15. Remove the heater hoses from the heater hose separator.
    Fig 9: Locating Heater Hoses Of Heater Hose Separator
    G07466813Courtesy of FORD MOTOR CO.
  16. Remove the heater hoses from the heater hose tubes and position aside.
    Fig 10: Locating Heater Hoses
    G07466814Courtesy of FORD MOTOR CO.
  17. Remove the heater hoses from the heater core and position aside.
    Fig 11: Locating Heater Hoses Of Heater Core
    G07466815Courtesy of FORD MOTOR CO.
  18. Remove the Thermostatic Expansion Valve (TXV) manifold fastener and the TXV  manifold.
    • Discard the O-ring seals.
      Fig 12: Locating Thermostatic Expansion Valve (TXV) Manifold And Fastener
      G07466816Courtesy of FORD MOTOR CO.
  19. Remove the RH and LH instrument panel upper cowl bolts.
  20. Remove the front seats. For additional information, refer to SEAT SYSTEM .
  21. Remove the instrument panel upper part. For additional information, refer to INSTRUMENT PANEL UPPER SECTION  in this information.
  22. Disconnect the LH instrument panel bulkhead electrical connector.
    Fig 13: Locating LH Instrument Panel Bulkhead Electrical Connector
    G07466817Courtesy of FORD MOTOR CO.
  23. Disconnect the 2 Smart Junction Box (SJB) lower electrical connectors and the lower bulkhead electrical connector.
    Fig 14: Locating Smart Junction Box (SJB) Lower And Lower Bulkhead Electrical Connectors
    G07466818Courtesy of FORD MOTOR CO.
  24. Remove and discard the steering column shaft-to-steering column bolt.
    Fig 15: Locating Steering Column Shaft-To-Steering Column Bolt
    G07466819Courtesy of FORD MOTOR CO.
  25. Detach the steering column shaft from the steering column.
  26. Remove the driver footrest pad.
    • Remove the 2 pin-type retainers.
      Fig 16: Locating Driver Footrest Pad And Pin-Type Retainers
      G07466820Courtesy of FORD MOTOR CO.
    27. NOTE: To avoid damaging the carpet with coolant when the instrument panel is removed, the carpet must be removed.
  27. Remove the LH and RH front carpet portions.
    • Remove the 2 pin-type retainers.
  28. If equipped, remove the 2 pin-type retainers and the rear footwell duct.
    Fig 17: Locating Rear Footwell Duct Pin-Type Retainers
    G07466821Courtesy of FORD MOTOR CO.
  29. Disconnect the RH bulkhead electrical connector, antenna cable and if equipped, the satellite radio antenna connector.
    Fig 18: Locating RH Bulkhead Electrical Connector, Antenna Cable And Satellite Radio Antenna Connector
    G07466822Courtesy of FORD MOTOR CO.
  30. Remove the 2 bolts and the ground wires.
    Fig 19: Locating Ground Wires Bolts
    G07466823Courtesy of FORD MOTOR CO.
  31. Disconnect the Restraints Control Module (RCM) small electrical connector and detach the 2 wire harness pin-type retainers.
    Fig 20: Locating Restraints Control Module (RCM) Small Electrical Connector And Wire Harness Pin-Type Retainers
    G07466824Courtesy of FORD MOTOR CO.
  32. Remove the 4 instrument panel center support bracket bolts.
    33. NOTE: An assistant is required when carrying out this step.
    NOTE: Remove the bolts from one side of the in-vehicle cross beam and support the in-vehicle cross beam before removing the bolts from the opposite side.
  33. Remove the 3 LH and 3 RH instrument panel side bolts.
    34. NOTE: To avoid damaging the RH front door trim panel when removing the in-vehicle cross beam from the vehicle, an assistant is required when carrying out this step.
    NOTE: Make sure that all electrical connectors and wiring are not hindered before removing the in-vehicle cross beam or damage to the components may occur.
  34. Remove the in-vehicle cross beam from the vehicle.
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