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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:

    REFER to COOLING SYSTEM DRAINING, FILLING AND BLEEDING - 2.0L GTDI , or

    REFER to COOLING SYSTEM DRAINING, FILLING AND BLEEDING - 3.5L TI-VCT .

  3. Recover the refrigerant:

    If equipped with DATC, REFER to AIR CONDITIONING (AC) SYSTEM RECOVERY, EVACUATION, AND CHARGING .

    If equipped with EMTC, REFER to AIR CONDITIONING (AC) SYSTEM RECOVERY, EVACUATION AND CHARGING .

  4. Remove the wiper arms. REFER to WIPER PIVOT ARM - FRONT .
  5. Remove the cowl panel grille. REFER to COWL PANEL GRILLE .
  6. Disconnect the 3 PCM electrical connectors and position the harness aside.
    Fig 1: Removing PCM Electrical Connectors
    G07429274Courtesy of FORD MOTOR CO.
    • Detach the PCM harness retainer.
  7. Remove the 2 PCM nuts and remove the PCM.
    • To install, tighten to 8 Nm (71 lb-in).
      Fig 2: Locating Powertrain Control Module Nuts
      G07429312Courtesy of FORD MOTOR CO.
  8. NOTE: LH side shown in illustration, RH side similar.

    Remove the strut tower cross brace.

    • To install, tighten to 55 Nm (41 lb-ft).
      Fig 3: Locating Strut Tower Cross Brace Nuts
      G07429276Courtesy of FORD MOTOR CO.
  9. Remove the heater hoses from the heater core and position aside.
    Fig 4: Locating Heater Hoses Clamps
    G07429277Courtesy of FORD MOTOR CO.
  10. Remove the TXV manifold fastener and the manifold.
    • Discard the O-ring seals.
    • To install, tighten to 8 Nm (71 lb-in).
  11. Remove the LH and RH instrument panel-to-front of dash bolts.
    • To install, tighten to 25 Nm (18 lb-ft).
      Fig 5: Locating Dash Bolts
      G07429278Courtesy of FORD MOTOR CO.
  12. Remove both front seats. REFER to REMOVAL AND INSTALLATION .
  13. Remove the instrument panel upper section. REFER to Instrument Panel Upper Section .
  14. Disconnect the LH instrument panel bulkhead electrical connector and the 2 lower SJB electrical connectors.
    • Detach the instrument panel bulkhead electrical connector push pin from the SJB.
    Fig 6: Disconnecting Left Hand Instrument Panel Bulkhead Electrical Connector
    G07429286Courtesy of FORD MOTOR CO.
  15. Remove the drivers foot rest pad.
    Fig 7: Removing Drivers Foot Rest Pad
    G07429287Courtesy of FORD MOTOR CO.
  16. Detach the retainers and remove the LH and RH front floor carpet sections.
    Fig 8: Locating LH And RH Front Floor Carpet Retainers
    G07429288Courtesy of FORD MOTOR CO.
  17. Disconnect the lower LH cowl bulkhead electrical connector.
    Fig 9: Removing Lower LH Cowl Bulkhead Electrical Connector
    G07429289Courtesy of FORD MOTOR CO.
  18. If equipped, detach the 2 retainers and remove the rear foot well duct.
    Fig 10: Locating Rear Foot Well Duct Retainers
    G07429290Courtesy of FORD MOTOR CO.
  19. Disconnect the RH bulkhead electrical connector and the antenna cable connector.
    Fig 11: Releasing Antenna Connector From Main Harness
    G07429291Courtesy of FORD MOTOR CO.
  20. Remove the 2 bolts and the ground wires.
    • To install, tighten to 10 Nm (89 lb-in).
      Fig 12: Locating Ground Wires Bolts
      G07429292Courtesy of FORD MOTOR CO.
  21. Disconnect the RCM small electrical connector.
    • Detach the 3 wiring harness retainers.
    Fig 13: Locating Wiring Harness Retainers
    G07429293Courtesy of FORD MOTOR CO.
  22. NOTE: RH side shown in illustration, LH side similar.

    Remove the 4 in-vehicle cross beam center support bracket bolts.

    • To install, tighten to 25 Nm (18 lb-ft).
      Fig 14: Locating Instrument Panel Center Support Bracket Bolts
      G07429294Courtesy of FORD MOTOR CO.
  23. NOTE: To avoid damaging the in-vehicle cross beam, an assistant is required when carrying out the following steps.
    NOTE: RH side shown in illustration, LH side similar.
    NOTE: Remove the bolts from one side completely and support the in-vehicle cross beam before removing the bolts from the opposite side.

    Remove the 3 LH and the 3 RH in-vehicle cross beam side bolts.

    • To install, tighten to 40 Nm (30 lb-ft).
      Fig 15: Locating RH Instrument Panel Side Bolts
      G07429295Courtesy of FORD MOTOR CO.
  24. NOTE: Make sure not to damage the RH front door trim panel or the in-vehicle cross beam when removing from the vehicle.
    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.

    Remove the in-vehicle cross beam from the vehicle.

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