Section 7 (Automatic Transmission - 6-Speed Automatic Transmission - 6F35 (2 Of 2)): Removal: Transmission

For information on Ford Color Coded Illustrations refer to OEM COLOR CODING

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	303-1554 Engine Support Bar
Courtesy of FORD MOTOR COMPANY	307-566 Retainer, Torque Converter TKIT-2006C-FFMFLM TKIT-2006C-LM TKIT-2006C-ROW
Magnetic Socket
Tie Rod End Remover
Transmission Jack
Retaining Strap
Wooden Block

1. With the vehicle in NEUTRAL, position it on a hoist. Refer to: Jacking and Lifting - Overview .
2. Remove the battery tray. Refer to: Battery Tray - 2.5L Duratec (125kW/170PS) .
3. Remove the battery tray support bracket.
   • Detach the wiring harness retainers and position the wiring harness aside.
   • Remove the nuts and the battery tray support bracket.

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4. Remove the bolts, disconnect the selector lever cable end from the manual lever and position the selector lever cable and bracket aside.

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5. Remove the nut and position aside the coolant hose.

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6. Remove the upper bellhousing bolts and position the ground cable aside.

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7. Remove the retainers and the underbody shield.

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8. NOTE: Make sure that the component terminals are not bent or damaged.

   Remove the wiring harness retainers and disconnect the transmission and TSS connectors.

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9. Remove the wiring harness retainers, nuts and remove the wiring harness bracket.

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10. Remove the wiring harness retainer bracket nut and position aside the wiring harness.

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11. Remove the nuts, bolts and position aside the transmission fluid cooler tubes and bypass valve.

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12. NOTE: Make sure that no component falls off during removal.

    Remove the transmission fluid cooler outlet tube band seals and backing rings.

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13. Remove the starter motor. Refer to: Starter Motor .
14. Remove the starter motor insulator.

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15. NOTE: Note the position of the components before removal.
    NOTE: Only rotate the crankshaft in a clockwise direction.

    Mark the torque converter stud with the flexplate before removal. Remove and discard the 4 nuts. Use the General Equipment: Magnetic Socket

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16. NOTE: If transmission disassembly or installation of a new transmission is necessary, drain the transmission fluid.
    NOTE: Be prepared to collect escaping fluid.

    Remove the transmission fluid drain plug and drain the fluid.

    Torque: 159 lb.in (18 Nm)

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17. Remove the front wheels and tires. Refer to: WHEELS AND TIRES .
18. Remove the retainers and position aside the LH fender splash shield.

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19. Remove the bolts and the front support bar.

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20. Remove the LH halfshaft. Refer to: Front Halfshaft LH .
21. NOTE: Do not use a hammer to separate the tie-rod end from the wheel knuckle or damage to the wheel knuckle can result.
    NOTE: Use care when installing the tie-rod end separator or damage to the outer tie-rod end boot may occur.

    Remove and discard the RH tie rod end nut. Remove the RH tie rod end from the knuckle. Use the General Equipment: Tie Rod End Remover

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22. Remove the RH flexible brake hose bolt.

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23. NOTE: Do not use a prying device to open the slot in the knuckle to separate the lower ball joint from the knuckle assembly. Damage to the knuckle assembly may occur.
    NOTE: Do not use a prying device or separator fork between the ball joint and the wheel knuckle. Damage to the ball joint or ball joint seal may result. Only use the pry bar by inserting it into the lower arm body opening.
    NOTE: Use care when releasing the lower arm and wheel knuckle into the resting position or damage to the ball joint seal may occur.

    Remove and discard the RH lower ball joint nut and bolt. Disconnect the lower arm and position aside the ball joint seal.

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24. Remove and discard the halfshaft retaining strap and the halfshaft retaining strap nuts.

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25. NOTE: Make sure that the strut is not moved more than necessary to prevent damage to top mount.
    NOTE: The inner constant velocity (CV) joint must not be bent more than 18°.
    NOTE: The outer constant velocity (CV) joint must not be bent more than 45°.

    Position aside and support the RH halfshaft.

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26. Remove the engine-to-bellhousing bolt.

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27. Remove the bellhousing bolts.

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28. Remove the nuts and the catalytic converter bracket.

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29. Remove the roll restrictor bracket bolts.

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30. Remove the bolts and the roll restrictor and bracket.

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31. NOTE: Use caution when lowering the vehicle after the special tool is installed. If the vehicle is lowered onto the special tool, damage to the special tool or the vehicle can occur.

    Install the special tool and support the engine. Use Special Service Tool: 303-1554 Engine Support Bar.

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32. Remove the bolt and the transmission support insulator.

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33. Remove the bolts and the transmission support insulator bracket.

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34. Secure the transmission to a transmission jack using a retaining strap. Use the General Equipment: Transmission Jack Use the General Equipment: Wooden Block Use the General Equipment: Retaining Strap

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35. Remove the bellhousing bolts on both sides.

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36. NOTE: Make sure that no part of the wiring harness is trapped.
    NOTE: Make sure that no components catch.

    Using the transmission jack, lower the transmission.

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37. Install Special Service Tool: 307-566 Retainer, Torque Converter.

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38. NOTE: The following steps are only necessary if overhauling or installing a new or remanufactured transmission.

    Flush the transmission fluid cooler. Refer to: Transmission Fluid Cooler - Backflushing and Cleaning .