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Section 1619 (Manual Transaxle (G6M)): Removal: Transaxle

WARNING: This page is about a different car, the 2012 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOLS

G08024480
 Powertrain Lift
300-OTC1585AE or equivalent
G08024481
 Support Bar, Engine
303-F072
WARNING: Do not breathe dust or use compressed air to blow dust from storage containers or friction components. Remove dust using government-approved techniques. Friction component dust may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure to follow these instructions may result in serious personal injury.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Remove the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  3. Remove the Air Cleaner (ACL) assembly. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - 2.5L .
  4. Disconnect the shift cables from the transaxle shift control lever, using a suitable tool to lightly pry them off the transaxle shift control lever.
    Fig 1: Locating Shift Cables And Transaxle Shift Control Lever
    G08024482Courtesy of FORD MOTOR CO.
    5. NOTE: Carefully pry the retainer on the shift cables. Do not damage the shift cable retainers. Using a small screwdriver push from the back.
    Fig 2: Locating Transaxle Bracket Shift Cables
    G08024483Courtesy of FORD MOTOR CO.
  5. Disconnect the shift cables from the transaxle bracket.
  6. Install the Engine Support Bar.
    Fig 3: Identifying Engine Support Bar (303-F072)
    G08024484Courtesy of FORD MOTOR CO.
  7. Detach the wire harness from the transaxle.
  8. Remove the 3 upper transaxle-to-engine bolts.
    9. NOTE: If one or both of the mount studs are removed or come out, do not reinstall the old stud(s). Install a new stud(s). Make sure the studs are properly seated in the case, even if they were not replaced.
  9. Remove the transaxle rear support insulator nuts and the transaxle rear support insulator bolt.
    10. NOTE: Use a steering wheel holding device such as Hunter® 28-75-1 or equivalent, to hold the steering wheel.
    Fig 4: Holding Steering Wheel In Straight-Ahead Position Using Suitable Holding Device
    G08024485Courtesy of FORD MOTOR CO.
  10. Using a suitable holding device, hold the steering wheel in the straight-ahead position.
  11. Remove the 2 nuts and the steering joint cover.
    Fig 5: Locating Nuts And Steering Joint Cover
    G08024486Courtesy of FORD MOTOR CO.
    12. 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. For additional information, refer to SUPPLEMENTAL RESTRAINT SYSTEM .
    Fig 6: Locating Steering Column Shaft To Steering Gear Mounted Bolt
    G08024487Courtesy of FORD MOTOR CO.
  12. Remove and discard the bolt and disconnect the steering column shaft from the steering gear.
  13. If equipped, remove the 7 screws and the underbody cover.
    Fig 7: Locating Underbody Cover Screws
    G08024488Courtesy of FORD MOTOR CO.
    14. NOTE: If disassembly of the transaxle is required, remove the drain plug and drain the transaxle.
    Fig 8: Locating Transaxle Drain Plug
    G08024489Courtesy of FORD MOTOR CO.
  14. Remove the drain plug and drain the transaxle.
  15. Once fluid has drained, install the drain plug.
    • Tighten to 49 Nm (36 lb-ft).
  16. Remove the 2 clutch tube hydraulic line bracket bolts.
    Fig 9: Locating Clutch Tube Hydraulic Line Bracket Bolts
    G08024490Courtesy of FORD MOTOR CO.
  17. Remove the 2 bolts and position the clutch slave cylinder aside.
    Fig 10: Locating Clutch Slave Cylinder Bolts
    G08024491Courtesy of FORD MOTOR CO.
  18. Disconnect the reverse lamp switch electrical connector.
  19. Remove the starter motor. For additional information, refer to STARTING SYSTEM .
  20. Disconnect the Output Shaft Speed (OSS) electrical connector.
    Fig 11: Locating Output Speed Sensor Electrical Connector
    G08024492Courtesy of FORD MOTOR CO.
    21. NOTE: Remove the steering gear/dash seal or damage to the seal may occur.
    Fig 12: Identifying Steering Gear/Dash Seal Clips
    G08024493Courtesy of FORD MOTOR CO.
  21. Release the 4 clips and slide the steering gear/dash seal off of the steering gear.
  22. Remove the exhaust flexible pipe. For additional information, refer to EXHAUST SYSTEM .
  23. Remove the 2 roll restrictor bracket bolts.
    Fig 13: Locating Roll Restrictor Bracket Bolts
    G08024494Courtesy of FORD MOTOR CO.
  24. Remove the 4 screws and position the RH fender splash shield aside.
    Fig 14: Locating RH Fender Splash Shield Mounting Screws
    G08024495Courtesy of FORD MOTOR CO.
  25. Remove the 6 pin-type retainers (4 shown in illustration) and the RH splash shield.
    Fig 15: Locating LH Splash Shield And Pin-Type Retainers
    G08024496Courtesy of FORD MOTOR CO.
  26. Remove the 4 screws and position the LH fender splash shield aside.
    Fig 16: Locating LH Fender Splash Shield Mounting Screws
    G08024497Courtesy of FORD MOTOR CO.
  27. Remove the 6 pin-type retainers (4 shown in illustration) and the LH splash shield.
    Fig 17: Locating LH Fender Splash Shield Pin-Type Retainers
    G08024498Courtesy of FORD MOTOR CO.
  28. Remove the LH halfshaft and the intermediate shaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
  29. Disconnect the 2 in-lineElectronic Power Assist Steering (EPAS) system electrical connectors at the front of the subframe.
    Fig 18: Locating Electronic Power Assist Steering (EPAS) System Electrical Connectors
    G08024499Courtesy of FORD MOTOR CO.
  30. Detach the 2 EPAS system wiring harness pin-type retainers from the subframe.
    Fig 19: Locating EPAS System Wiring Harness Pin-Type Retainer
    G08024500Courtesy of FORD MOTOR CO.
  31. Detach the EPAS system wiring harness pin-type retainer from the subframe under the LH fender splash shield.
    Fig 20: Locating EPAS System Wiring Harness Pin-Type Retainer From Subframe Under LH Fender Splash Shield
    G08024501Courtesy of FORD MOTOR CO.
  32. Remove the bolt and the EPAS system wiring harness ground from behind the RH splash shield.
    Fig 21: Locating Electronic Power Assist Steering (EPAS) System Wiring Harness Ground Mounting Bolt
    G08024502Courtesy of FORD MOTOR CO.
    33. NOTE: LH shown in illustration, RH similar.
    Fig 22: Locating Stabilizer Bar Link Nut
    G08024503Courtesy of FORD MOTOR CO.
  33. Remove the nuts and separate the stabilizer bar links from the struts.
  34. Position the Powertrain Lift under the subframe assembly.
    Fig 23: Positioning Powertrain Lift Under Subframe Assembly
    G08024504Courtesy of FORD MOTOR CO.
    35. NOTE: LH shown in illustration, RH similar.
    Fig 24: Locating Subframe Bracket-To-Body Bolts
    G08024505Courtesy of FORD MOTOR CO.
  35. Remove the subframe bracket-to-body bolts.
    36. NOTE: LH shown in illustration, RH similar.
    Fig 25: Locating Rear Subframe Nut And Subframe Bracket
    G08024506Courtesy of FORD MOTOR CO.
  36. Remove the rear subframe nuts and the subframe brackets.
    37. NOTE: LH shown in illustration, RH similar.
    Fig 26: Locating Front Subframe Nut
    G08024507Courtesy of FORD MOTOR CO.
  37. Remove the front subframe nuts.
  38. Lower the subframe assembly from the vehicle.
  39. Support the transaxle with a suitable transmission jack. Secure the transaxle to the transmission jack with a safety strap.
  40. Remove the clutch housing-to-oil pan bolt.
    Fig 27: Locating Clutch Housing-To-Oil Pan Bolt
    G08024508Courtesy of FORD MOTOR CO.
  41. Remove the 2 oil pan-to-clutch housing bolts.
    Fig 28: Locating Oil Pan-To-Clutch Housing Bolts
    G08024509Courtesy of FORD MOTOR CO.
  42. Remove the remaining 4 transaxle-to-engine bolts.
  43. Move the transaxle away from the engine and lower it from the vehicle.
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