Section 37 (ENGINE - 3.5L DURATEC (212kW/278PS)): Removal: Engine

For information on Ford Color Coded Illustrations refer to OEM Color Coding

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	303-1245 Engine Lift Eye TKIT-2006UF-FLM TKIT-2006UF-ROW
Courtesy of FORD MOTOR COMPANY	303-1529 Lift Eye, Engine TKIT-2010A-F TKIT-2010A-LM TKIT-2010A-ROW
Courtesy of FORD MOTOR COMPANY	307-346 (T97T-7902-A) Retainer, Torque Converter TKIT-1998-LM (NavigatoR) TKIT-1997-F/FLM/LT
Courtesy of FORD MOTOR COMPANY	307-569 Disconnect Tool TOC Line (1/2) TKIT-2006U-F/FM TKIT-2006U-FLM/LM TKIT-2006U-ROW1 TKIT-2006U-ROW2
Floor Crane
Adjustable Mounting Arm
Oil Drain Equipment
Hose Clamp Remover/Installer
Powertrain Jack
Wooden Block

2WD/4WD 

1. With the vehicle in NEUTRAL, position it on a hoist. Refer to: Jacking and Lifting - Overview .
2. Release the fuel pressure. Refer to: Fuel System Pressure Release .
3. NOTE: Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent).

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

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4. NOTE: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring can occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. Refer to Clockspring or Clockspring - Vehicles With: Adaptive Steering .
   • Remove and discard the steering intermediate shaft bolt.
   • Separate the steering intermediate shaft from the steering gear.

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5. Remove the engine appearance cover.

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6. Recover the A/C system. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging .
7. Drain the engine cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .
8. Remove the following items:
   1. Remove the degas bottle. Refer to: Degas Bottle .
   2. Remove the accessory drive belt. Refer to: Accessory Drive Belt .
   3. Remove the air cleaner. Refer to: Air Cleaner .
   4. Remove the air cleaner outlet pipe. Refer to: Air Cleaner Outlet Pipe .
   5. Remove the battery tray. Refer to: Battery Tray .

9. Remove the stud bolt and position aside the ground cable.

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10. Disconnect the junction box electrical connector.

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11. 1. Release the tabs.
    2. Lift and position top part of junction box aside.

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12. Release the tabs and open the cover.

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13. Remove the nuts and disconnect the electrical wiring harness cables.

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14. Remove the bolt and disconnect the wire harness retainer. Position aside the wire harness.

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15. Disconnect the vacuum hose and the EVAP tube. Refer to: Quick Release Coupling . Use the General Equipment: Hose Clamp Remover/Installer

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16. Disconnect the fuel supply tube. Refer to: Spring Lock Couplings .

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17. Remove the bolt. Disconnect and position aside the transaxle control cable aside.

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18. • Disconnect the upper and lower radiator hoses. Use the General Equipment: Hose Clamp Remover/Installer
    • Disconnect the heater hoses. Use the General Equipment: Hose Clamp Remover/Installer

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19. Remove the bolt for the A/C tube bracket.

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20. • NOTE: Make sure that all openings are sealed.

      Disconnect the A/C pressure switch. Remove the nut and disconnect the A/C hose.

    • Remove and discard the O-ring.

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21. • NOTE: Make sure that all openings are sealed.

      Remove the nut and disconnect the A/C tube fitting.

    • Remove and discard the O-ring.

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22. Disconnect the electrical connector and the wire harness retainer.

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23. Disconnect the PCM electrical connector and the wire harness retainer.

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24. Remove the bolt and disconnect the wire retainer. Position aside the ground wire.

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25. Remove the degas bottle hose.

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26. Remove the following items:
    1. Remove the cooling fan motor and shroud. Refer to: Cooling Fan Motor and Shroud .
    2. Remove the front wheels and tires. Refer to: Wheel and Tire .
    3. Remove the fender splash shields. Refer to: Fender Splash Shield .

27. Remove the retainers and the underbody shields.

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28. Remove the retainers and the underbody shields.

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29. Detach and disconnect the engine harness electrical connector.

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30. Remove the transmission fluid cooler tube secondary latches.

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31. Using the special tool, disconnect the transmission fluid cooler tubes from the transmission fluid cooler thermal bypass valve. Use Special Service Tool: 307-569 Disconnect Tool TOC Line (1/2).

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32. Remove the bolt and the LH anti-lock sensor.

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33. Remove the bolt and the RH anti-lock sensor.

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34. NOTE: Use the internal or external hex-holding feature to prevent the ball and stud from turning while removing or installing the stabilizer bar link nuts. The link boot seal must not be allowed to twist while loosening the link nuts or damage to the boot seal will occur.

    Remove the nut and position the LH sway bar link.

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35. NOTE: Use the internal or external hex-holding feature to prevent the ball and stud from turning while removing or installing the stabilizer bar link nuts. The link boot seal must not be allowed to twist while loosening the link nuts or damage to the boot seal will occur.

    Remove the nut and position the RH sway bar link.

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36. NOTE: Do not allow the brake caliper and the anchor plate assembly to hang from the brake hose or damage to the hose can occur.

    Remove the front brake discs. Refer to: Brake Disc .

37. If equipped, disconnect the oil cooler hoses. Use the General Equipment: Hose Clamp Remover/Installer

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38. Disconnect the coolant hose retainer.

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39. Remove the exhaust Y-pipe. Refer to: Exhaust Y-Pipe .
40. Remove the retainers and the inspection cover.

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41. Remove and discard the torque converter bolts.

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42. Remove the oil pan-to-transaxle bolts.

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43. Remove the drain plug and drain the engine oil. Use the General Equipment: Oil Drain Equipment

    Torque: 20 lb.ft (27 Nm)

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44. Remove and discard the engine oil filter. Use the General Equipment: Oil Drain Equipment

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    4WD 

45. NOTE: Index-mark the driveshaft for installation.
    • Remove the bolts and support the driveshaft with a length of mechanic's wire.
    • Discard the bolts.

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    2WD/4WD 

46. NOTE: RH side shown, LH side similar.

    Mark the subframe location.

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47. Using a 2 x 6 board, 50 in (1, 270 mm) and two 2 x 6 boards 24 in (609.6 mm), position the powertrain jack with the 50 in (1, 270 mm) board under the 2 control arms and the two 24 in (609.6 mm) boards under the transmission and oil pan. Use the General Equipment: Powertrain Jack. Use the General Equipment: Wooden Block

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48. Install the adjustable mounting arm from the powertrain jack table to the LH engine-to-transmission bolt hole. Use the General Equipment: Adjustable Mounting Arm

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49. Install a ratchet strap from the front of the subframe under the powertrain jack to the rear of the subframe, to secure the subframe to the powertrain jack.
50. NOTE: The struts will need to come off of the knuckles when the powertrain and subframe assembly is lowered.

    Remove the nuts and push the bolts out and remove. Discard the nuts and the bolts.

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51. NOTE: The struts will need to come off of the knuckles when the powertrain and subframe assembly is lowered.

    Remove the nuts and push the bolts out and remove. Discard the nuts and the bolts.

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52. Remove and discard the engine mount nuts.

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53. • Remove and discard the nut and bolts.
    • Remove the engine mount.

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54. Remove and discard the transmission mount bolts.

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55. • Remove and discard the subframe rear bolts.
    • Remove the subframe bolts and the crossmember.

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56. Remove and discard the subframe front bolts.

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57. Lower the subframe and powertrain assembly from the vehicle.

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58. Install Special Service Tool: 303-1245 Engine Lift Eye.

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59. Install Special Service Tool: 303-1529 Lift Eye, Engine.

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60. Using the Floor Crane and Spreader Bar, support the powertrain and subframe assembly. Use the General Equipment: Floor Crane

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61. Install a ratchet strap from the RH knuckle to the subframe to keep the RH halfshaft from coming out of the PTU (power transfer unit) or transmission.
62. Remove the starter wiring nuts.

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63. Disconnect the wire harness retainers and position aside.

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64. Remove the stud bolts and the starter.

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65. Disconnect the wire retainer and the transmission electrical connector.

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66. Remove the stud bolt and position aside the ground cable.

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67. Disconnect the RH electrical connectors and the wire retainer.

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68. Remove the bolts and the heat shield.

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69. • Remove the nuts and the RH catalytic converter.
    • Discard the nuts.

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70. • Remove and discard the exhaust manifold gasket.
    • Remove and discard the exhaust manifold studs.

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71. • Position back the boot and remove the generator nut.
    • Disconnect the electrical connector and the wire retainers.

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72. Disconnect the wire harness retainers and position aside the wiring harness.

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    4WD 

73. Remove the bolts and the PTU (power transfer unit) bracket.

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74. Disconnect the PTU vent hose.

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    2WD/4WD 

75. Remove the adjustable mounting arm. Use the General Equipment: Adjustable Mounting Arm

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76. Remove the ratchet strap from the front of the subframe under the powertrain lift table to the rear of the subframe.
77. NOTE: LH shown, RH similar.

    Install the ratchet strap from the front subframe to the LH engine lift eye and from the rear of the subframe to the RH engine lift eye.

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78. NOTE: Position wood blocks under the engine and transmission.

    Using the Floor Crane and Spreader Bar, remove the powertrain and subframe as an assembly from the powertrain lift table and set on the ground. Use the General Equipment: Floor Crane

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79. NOTE: LH shown, RH similar.

    Remove the ratchet strap from the front subframe to the LH engine lift eye and from the rear of the subframe to the RH engine lift eye.

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80. Remove the bolts for the RH halfshaft bracket.

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81. Remove the transaxle-to-engine and the engine-to-transaxle bolts.

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82. • Remove the transaxle-to-engine bolts.
    • Separate the transaxle from the engine.

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83. Remove the engine from the transaxle. Use the General Equipment: Floor Crane

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84. Install Special Service Tool: 307-346 (T97T-7902-A) Retainer, Torque Converter.

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