LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2012 >> Explorer Limited, 3.5 8, AWD >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical - 3.5L-Ti-VCT >> Removal And Installation >> Engine - 2WD >> Removal

Engine - 2WD: Removal

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.
  1. With the vehicle in NEUTRAL, position it on a hoist. REFER to JACKING AND LIFTING for lifting points.
  2. Recover the A/C  system. REFER to AIR CONDITIONING (AC) SYSTEM RECOVERY, EVACUATION, AND CHARGING .
  3. Remove the cowl panel. REFER to COWL PANEL .
  4. Release the fuel system pressure. REFER to FUEL SYSTEM PRESSURE RELEASE .
  5. Remove the engine ACL assembly and ACL outlet pipe. REFER to INTAKE AIR SYSTEM COMPONENTS - EXPLODED VIEW .
  6. Remove the battery tray. REFER to BATTERY AND BATTERY TRAY - EXPLODED VIEW .
  7. Disconnect the engine wiring harness electrical connector.
    Fig 1: Identifying Engine Wiring Harness Electrical Connector
    G08029070Courtesy of FORD MOTOR CO.
  8. Remove the nut from the ground wire attached to the body.
    Fig 2: Locating Ground Wire To Body Attached Nut
    G08029071Courtesy of FORD MOTOR CO.
  9. Remove the stud bolt from the ground wire attached to the body.
    Fig 3: Locating Ground Wire Attached To Body Stud Bolt
    G08029072Courtesy of FORD MOTOR CO.
  10. Disconnect the power feed wire from the positive battery terminal.
    Fig 4: Disconnecting Power Feed Wire From Positive Battery Terminal
    G08029073Courtesy of FORD MOTOR CO.
  11. Remove the nut and disconnect the power feed wire from the positive battery terminal.
    Fig 5: Locating Positive Battery Terminal Nut
    G08029074Courtesy of FORD MOTOR CO.
  12. Drain the cooling system. REFER to COOLING SYSTEM DRAINING, FILLING AND BLEEDING - 3.5L TI-VCT .
  13. Remove the nut and disconnect the A/C  tube.
    1. Discard the O-ring seal and gasket seal.
    Fig 6: Locating A/C Tube And Mounting Nut
    G08028960Courtesy of FORD MOTOR CO.
  14. Disconnect the A/C  pressure switch electrical connector.
    Fig 7: Locating A/C Pressure Switch Electrical Connector
    G08029076Courtesy of FORD MOTOR CO.
  15. Remove the nut and disconnect the A/C  tube.
    1. Discard the O-ring seal and gasket seal.
    Fig 8: Locating A/C Tube And Mounting Nut
    G08029077Courtesy of FORD MOTOR CO.
  16. Disconnect the vent hose from the degas bottle.
    Fig 9: Locating Degas Bottle Vent Hose Clamp
    G08028961Courtesy of FORD MOTOR CO.
  17. If equipped, disconnect the degas bottle coolant hose from the engine coolant tube.
    Fig 10: View Of Degas Bottle Coolant Hose Connected -To- Engine Coolant Tube
    G08028962Courtesy of FORD MOTOR CO.
  18. Disconnect the brake booster vacuum hose from the upper intake manifold.
    Fig 11: Locating Power Brake Booster Vacuum Supply Hose
    G07417495Courtesy of FORD MOTOR CO.
  19. Disconnect the EVAP tube. REFER to QUICK CONNECT COUPLING from the upper intake manifold.
    Fig 12: Locating Evaporative Emission Canister Vent Solenoid
    G07417494Courtesy of FORD MOTOR CO.
  20. Disconnect the engine harness electrical connector.
    Fig 13: Identifying Engine Harness Electrical Connector
    G08029082Courtesy of FORD MOTOR CO.
  21. Detach the wiring harness retainer.
    Fig 14: View Of PCM And Engine Harness Electrical Connectors
    G08029083Courtesy of FORD MOTOR CO.
  22. Disconnect the 2 PCM electrical connectors.
    Fig 15: Locating PCM Electrical Connectors
    G07997858Courtesy of FORD MOTOR CO.
  23. Remove the engine wiring harness retainer from the bulkhead.
    1. Push the wiring harness retainer tab in.
    2. Slide the wiring harness up and out of the bulkhead.
    Fig 16: Locating Engine Wiring Harness Retainer At Bulkhead
    G06251573Courtesy of FORD MOTOR CO.
  24. Remove the bolts and the ground cables from the RH strut tower and engine front cover.
    Fig 17: Locating Ground Cables And Fasteners
    G07417529Courtesy of FORD MOTOR CO.
  25. Disconnect the fuel supply tube from the fuel rail. REFER to QUICK CONNECT COUPLING .
    Fig 18: Locating Fuel Supply Tube Quick Connect Coupling
    G07417510Courtesy of FORD MOTOR CO.
  26. Disconnect the upper radiator hose, lower radiator hose and 2 heater hoses from the thermostat housing.
    Fig 19: Locating Upper Radiator Hose, Lower Radiator Hose And Heater Hoses
    G07997860Courtesy of FORD MOTOR CO.
  27. Disconnect the transaxle control cable from the control lever.
    Fig 20: View Of Transaxle Control Cable And Transmission Control Lever
    G07997861Courtesy of FORD MOTOR CO.
  28. Disconnect the transaxle control cable from the shift cable bracket and detach the wiring harness pin-type retainer.
    Fig 21: Locating Shift Cable Bracket And Wiring Harness
    G07997862Courtesy of FORD MOTOR CO.
  29. If equipped, detach the engine block heater harness.
  30. Remove the LF and RF wheel and tire. REFER to WHEEL AND TIRE .
  31. NOTE: Apply the brake to keep the halfshafts from rotating.
    NOTE: RH shown in illustration, LH similar.

    Remove the RH and LH halfshaft nuts.

    1. Do not discard at this time.
    Fig 22: Locating Halfshaft Nuts
    G07997870Courtesy of FORD MOTOR CO.
  32. NOTE: RH shown in illustration, LH similar.

    Using 205-D070  (D93P-1175-B), separate the RH and LH halfshaft from the wheel hubs.

    Fig 23: Separating Halfshaft From Wheel Hub Using Front Wheel Hub Remover
    G06251585Courtesy of FORD MOTOR CO.
  33. NOTE: Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent).

    Using a suitable holding device, hold the steering wheel in the straight-ahead position.

    Fig 24: Holding Steering Wheel In Straight-Ahead Position Using Suitable Holding Device
    G06063988Courtesy of FORD MOTOR CO.
  34. Remove the 2 lower scrivets from the RF fender splash shield.
    Fig 25: Holding Steering Wheel
    G08029094Courtesy of FORD MOTOR CO.
  35. Remove the 2 lower scrivets from the LF fender splash shield.
    Fig 26: Locating LF Fender Splash Shield Lower Scrivets
    G08029095Courtesy of FORD MOTOR CO.
  36. Remove the bolt from the RH brake hose bracket.
    Fig 27: Location of Brake Hose Bracket Bolt
    G08029738Courtesy of FORD MOTOR CO.
  37. Remove the 3 twist lock retainers and the underbody air duct.
    Fig 28: Locating Underbody Air Duct And Twist Lock Retainers
    G07430766Courtesy of FORD MOTOR CO.
  38. NOTE: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring may occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. REFER to CLOCKSPRING .

    Remove the bolt and disconnect the steering column shaft from the steering gear.

    1. Discard the bolt.
    Fig 29: Identifying Steering Intermediate Shaft, Steering Gear And Fastener
    G08029098Courtesy of FORD MOTOR CO.
  39. Remove the exhaust Y-pipe. REFER to EXHAUST Y-PIPE .
  40. Remove the drain plug and drain the engine oil.
    1. Install the drain plug and tighten to 27 Nm (20 lb-ft).
    Fig 30: Disconnecting Steering Column Shaft From Steering Gear
    G06061972Courtesy of FORD MOTOR CO.
  41. Remove and discard the engine oil filter.
    Fig 31: Locating Engine Oil Drain Plug
    G07999972Courtesy of FORD MOTOR CO.
  42. Detach the oil cooler hose support clip from the subframe.
    Fig 32: Locating Engine Oil Filter
    G06279484Courtesy of FORD MOTOR CO.
  43. NOTE: Do not rotate the roll restrictor with the subframe bolt tight. This may damage the insulator assembly.

    Remove the 2 rear engine roll restrictor-to-transaxle bolts and the bracket.

    Fig 33: Locating Oil Cooler Coolant Hose Retainer
    G08029744Courtesy of FORD MOTOR CO.
  44. NOTE: RH shown in illustration, LH similar.

    Remove and discard the upper stabilizer link nuts.

    Fig 34: Locating Engine Roll Restrictor-To-Frame Bolt
    G07997883Courtesy of FORD MOTOR CO.
  45. NOTE: Use the hex-holding feature to prevent the stud from turning while removing the nut.
    NOTE: RH shown in illustration, LH similar.

    Remove and discard the tie-rod end nuts.

    1. Separate the tie-rod ends from the wheel knuckles.
    Fig 35: Locating Upper Stabilizer Link Nuts
    G07997884Courtesy of FORD MOTOR CO.
  46. NOTE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part number or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts.
    NOTE: Use care when releasing the lower arm and knuckle into the resting position or damage to the ball joint seal or CV boot may occur.
    NOTE: Use the hex-holding feature to prevent the stud from turning while removing the nut.
    NOTE: RH shown in illustration, LH similar.

    Remove and discard the lower ball joint-to-wheel knuckle nuts.

    1. Separate the lower ball joints from the wheel knuckles.
    Fig 36: Locating Tie-Rod End And Nut
    G08029747Courtesy of FORD MOTOR CO.
  47. Remove the bolt and position the EPAS heat shield aside.
    Fig 37: Locating Ball Joint Nut
    G08029107Courtesy of FORD MOTOR CO.
  48. Remove the bolt for the EPAS wiring harness bracket.
    Fig 38: Locating EPAS Heat Shield Bolts
    G08029108Courtesy of FORD MOTOR CO.
  49. Disconnect the 2 EPAS electrical connectors.
    Fig 39: Locating EPAS Wiring Harness Bracket Bolt
    G08029109Courtesy of FORD MOTOR CO.
  50. Detach the EPAS wiring harness pin-type retainer from the steering gear.
    Fig 40: Locating EPAS Electrical Connectors
    G08029110Courtesy of FORD MOTOR CO.
  51. Using a wax pencil (or equivalent) apply witness marks to the vehicle and subframe to aid in installation.
  52. Position 300-OTC1585AE  under the subframe assembly.
    Fig 41: Locating EPAS Wiring Harness Pin-Type Retainer
    G08029111Courtesy of FORD MOTOR CO.
  53. NOTE: RH shown in illustration, LH similar.

    Remove the subframe bracket-to-body bolts.

    Fig 42: Supporting Subframe Assembly Using Jack
    G08029112Courtesy of FORD MOTOR CO.
  54. NOTE: RH shown in illustration, LH similar.

    Remove the rear subframe bolts and the subframe brackets.

    Fig 43: Locating Subframe Bracket-To-Body Bolts
    G08029113Courtesy of FORD MOTOR CO.
  55. NOTE: RH shown in illustration, LH similar.

    Remove the front subframe bolts.

    Fig 44: Locating Rear Subframe Bolt And Subframe Bracket
    G06251604Courtesy of FORD MOTOR CO.
  56. Lower the subframe assembly from the vehicle.
  57. Pull the RH wheel knuckle outward and rotate it toward the rear of the vehicle.
    1. Separate the halfshaft from the wheel knuckle.
    2. Secure the RH wheel knuckle assembly.
    Fig 45: Pulling RH Wheel Knuckle Outward
    G06251605Courtesy of FORD MOTOR CO.
  58. Remove the 2 intermediate shaft bracket nuts.
    Fig 46: Pulling RH Wheel Knuckle Assembly
    G08029757Courtesy of FORD MOTOR CO.
  59. Remove the RH intermediate and halfshaft as an assembly.
  60. Pull the LH wheel knuckle outward and rotate it toward the rear of the vehicle.
    1. Separate the halfshaft from the wheel knuckle.
    2. Secure the LH wheel knuckle assembly.
    Fig 47: Pulling LH Wheel Knuckle Outward
    G08029117Courtesy of FORD MOTOR CO.
    Fig 48: Pulling RH Wheel Knuckle Outward
    G06251605Courtesy of FORD MOTOR CO.
  61. NOTE: The sharp edges on the stub shaft splines can slice or puncture the oil seal. Use care when inserting the stub shaft into the transmission or damage to the component may occur.

    Using 100-001  (T50T-100-A) and 205-832  , remove the LH halfshaft from the transmission.

    Fig 49: Separating Halfshaft From Transmission
    G06065036Courtesy of FORD MOTOR CO.
  62. Remove and discard the circlip from the stub shaft.
    Fig 50: Removing Halfshaft From Transmission Using Slide Hammer And Halfshaft Remover
    G07957718Courtesy of FORD MOTOR CO.
  63. Remove the 2 RH halfshaft support bracket studs.
    Fig 51: Locating Stub Shaft Circlip
    G08029120Courtesy of FORD MOTOR CO.
  64. Remove the 2 bolts and the RH halfshaft support bracket.
    Fig 52: Locating RH Halfshaft Support Bracket Studs
    G08029121Courtesy of FORD MOTOR CO.
  65. If equipped, disconnect the oil cooler coolant hoses.
    Fig 53: Locating RH Halfshaft Support Bracket
    G06279497Courtesy of FORD MOTOR CO.
  66. Remove the 2 secondary latches from the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.
    Fig 54: Locating Oil Cooler Coolant Hoses Retainers
    G06062156Courtesy of FORD MOTOR CO.
  67. Using 307-569  , disconnect the transmission fluid cooler tubes from the transmission fluid cooler thermal bypass valve.
    Fig 55: Locating Transmission Fluid Cooler Tubes Secondary Latches
    G06062157Courtesy of FORD MOTOR CO.
  68. Remove the 2 fasteners and the inspection cover.
    Fig 56: Disconnecting Transmission Fluid Cooler Tubes From Transmission Fluid Cooler Thermal Bypass Valve
    G07998852Courtesy of FORD MOTOR CO.
  69. Remove and discard the 3 torque converter bolts.
    Fig 57: Locating Inspection Cover And Fasteners
    G07997899Courtesy of FORD MOTOR CO.
  70. Remove the 4 oil pan-to-transaxle bolts.
    Fig 58: Locating Torque Converter Bolt
    G07998853Courtesy of FORD MOTOR CO.
  71. Disconnect the RH CMS electrical connector.
    Fig 59: Locating RH CMS Electrical Connector
    G07397887Courtesy of FORD MOTOR CO.
  72. Remove the 4 nuts and the RH catalytic converter.
    1. Discard the nuts and gasket.
    Fig 60: Locating RH CMS Electrical Connector
    G07430767Courtesy of FORD MOTOR CO.
  73. NOTE: Position a block of wood under the transaxle.

    Install 300-OTC1585AE  and 014-00001  .

    Fig 61: Identifying Tightening Sequence Of RH Catalytic Converter Mounting Nuts
    G08029129Courtesy of FORD MOTOR CO.
  74. Remove the transaxle support insulator through bolt and nut.
    Fig 62: Positioning Block Of Wood Under Transaxle
    G07997906Courtesy of FORD MOTOR CO.
  75. Remove the 3 nuts, the bolt and the transaxle support insulator bracket.
    Fig 63: Locating Transaxle Support Insulator Bolt And Nut
    G07997907Courtesy of FORD MOTOR CO.
  76. Remove the 4 engine mount nuts, the 3 engine mount bolts and the engine mount.
    Fig 64: View Of Engine Mount And Fasteners
    G08028966Courtesy of FORD MOTOR CO.
  77. Lower the engine and transaxle assembly from the vehicle.
  78. Remove the starter motor solenoid cover.
    Fig 65: Locating Engine Mount Nuts And Bolts
    G07997911Courtesy of FORD MOTOR CO.
  79. Remove the 2 nuts and the starter motor wiring terminals.
    Fig 66: Locating Starter Motor Solenoid Cover
    G06062172Courtesy of FORD MOTOR CO.
  80. Remove the harness retainer, 2 stud bolts and the starter.
  81. Install 303-1245  on the LH cylinder head.
    Fig 67: Installing LH Cylinder Head Using Engine Lift Eye
    G07997915Courtesy of FORD MOTOR CO.
  82. Disconnect the transaxle control electrical connector.
    Fig 68: Installing LH Cylinder Head Using Engine Lift Eye
    G07997916Courtesy of FORD MOTOR CO.
  83. Detach the transaxle control wire harness retainer from the transaxle stud bolt.
    Fig 69: Locating Transaxle Control Electrical Connector
    G08029780Courtesy of FORD MOTOR CO.
  84. Detach the 2 EPAS wiring harness retainers from the transaxle stud bolts.
  85. Using 300-OTC1819E  and 303-D089  (D93P-6001-A3), remove the engine and transaxle from the lift table.
    Fig 70: Using Spreader Bar And Floor Crane To Move Engine
    G08029631Courtesy of FORD MOTOR CO.
  86. Remove the 2 engine-to-transaxle bolts.
    Fig 71: Removing Engine Using Spreader Bar And Floor Crane
    G07997919Courtesy of FORD MOTOR CO.
  87. Remove the 5 transaxle-to-engine bolts.
    1. Separate the transaxle from the engine.
    Fig 72: Locating Engine-To-Transaxle Bolts
    G07997920Courtesy of FORD MOTOR CO.
scientia non olet · About LEMON Manuals