Transaxle - 3.5L

Illustration	Tool Name	Tool Number
Courtesy of FORD MOTOR CO.	Adapter for 204-592	204-592/1
Courtesy of FORD MOTOR CO.	Bearing Cup Puller	308-047 (T77F-1102-A)
Courtesy of FORD MOTOR CO.	Engine Lifting Bracket	303-1245
Courtesy of FORD MOTOR CO.	Remover, Front Wheel Hub	205-D070 (D93P-1175-B) or equivalent
Courtesy of FORD MOTOR CO.	Separator, Ball Joint	204-592
Courtesy of FORD MOTOR CO.	Slide Hammer	100-001 (T50T-100-A)
Courtesy of FORD MOTOR CO.	Spreader Bar	303-1246
Courtesy of FORD MOTOR CO.	Support Bar, Engine	303-F072

All vehicles 

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING article.
2. Remove the battery and battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
3. Remove the air cleaner and the outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - 3.5L article.
4. Remove the upper intake manifold. For additional information, refer to ENGINE - 3.5L article.
5. Disconnect the selector lever cable end.
Fig 1: Locating Selector Lever Cable End
Courtesy of FORD MOTOR CO.
6. Remove the 2 bolts and the nut for the selector lever cable bracket and position the cable and bracket aside.
Fig 2: Identifying Selector Lever Cable Bracket Bolts & Nuts
Courtesy of FORD MOTOR CO.
7. Disconnect the wire harness from the Transmission Control Module (TCM).
Fig 3: Identifying Transmission Control Module Electrical Connector
Courtesy of FORD MOTOR CO.
8. Disconnect the wiring harness fasteners from the torque converter housing stud bolt and the starter motor.
Fig 4: Identifying Wiring Harness Fasteners & Torque Converter Housing Stud Bolt
Courtesy of FORD MOTOR CO.
9. Remove the 2 ground strap bolts and position aside the ground straps.
Fig 5: Identifying Ground Straps & Ground Strap Bolts
Courtesy of FORD MOTOR CO.
10. Position the boot back and remove the starter terminals from the starter.
Fig 6: Locating Bolts On Starter Terminals
Courtesy of FORD MOTOR CO.
11. Remove the 2 bolts and the starter.
Fig 7: Locating Starter Bolts
Courtesy of FORD MOTOR CO.
12. Remove the 4 upper torque converter housing bolts.
Fig 8: Identifying Upper Transaxle-To-Engine Bolts
Courtesy of FORD MOTOR CO.
13. Install the Engine Lifting Bracket on the LH cylinder head.
Fig 9: Special Tool (303-1245) On LH Cylinder Head
Courtesy of FORD MOTOR CO.
14. Install the Engine Support Bar and Spreader Bar to support the engine.
Fig 10: Installing Engine Support Bar & Spreader Bar To Support Engine
Courtesy of FORD MOTOR CO.
15. Remove the transaxle support insulator through bolt.
Fig 11: Identifying Transaxle Support Insulator Through Bolt
Courtesy of FORD MOTOR CO.
16. Using the Engine Support Bar, lower the transaxle and remove the 2 transaxle support insulator bracket nuts, the bolt and the bracket.
Fig 12: Locating Transaxle Support Insulator Bracket Nuts & Bolt
Courtesy of FORD MOTOR CO.
17. Remove the 4 screws and position the RH fender splash shield aside.
Fig 13: Locating RH Fender Splash Shield Screws
Courtesy of FORD MOTOR CO.
18. Remove the 6 pin-type retainers and remove the RH front structure to subframe splash shield.
Fig 14: Locating RH Front Structure-To-Subframe Splash Shield
Courtesy of FORD MOTOR CO.
19. Remove the 4 screws and position the LH fender splash shield aside.
Fig 15: Locating LH Fender Splash Shield Screws
Courtesy of FORD MOTOR CO.
20. Remove the pin-type retainers and remove the LH front structure-to-subframe splash shield.
Fig 16: Locating LH Front Structure-To-Subframe Splash Shield
Courtesy of FORD MOTOR CO.
21. Remove the 6 Y-pipe nuts and the Y-pipe assembly.
Fig 17: Locating Y-Pipe Nuts & Y-Pipe Assembly
Courtesy of FORD MOTOR CO.
NOTE: LH shown, RH similar.
22. Remove the nuts and separate the sway bar links from the struts.
Fig 18: Locating Sway Bar Links Nut
Courtesy of FORD MOTOR CO.
23. If a transaxle exchange or overhaul is required, the transmission fluid must be drained.
    • Remove the transmission drain plug and allow the transmission fluid to drain.
Fig 19: Identifying Transmission Drain Plug
Courtesy of FORD MOTOR CO.
24. If removed, install the transmission fluid drain plug.
    • Tighten to 47 Nm (35 lb-ft).
Fig 20: Identifying Transmission Drain Plug
Courtesy of FORD MOTOR CO.
25. Remove the LH halfshaft. For additional information, refer to FRONT DRIVE HALFSHAFTS article.

All-Wheel Drive (AWD) vehicles 

26. Remove and discard the front wheel hub nut.
Fig 21: Locating Front Wheel Hub Nut
Courtesy of FORD MOTOR CO.

All vehicles 

27. Remove the RH lower control arm nuts.
Fig 22: Locating Front And Rear Lower Control Arm Nuts
Courtesy of FORD MOTOR CO.
NOTE: When the lower ball joint is separated from the wheel knuckle, the lower arm may strike the outer constant velocity (CV) joint boot with enough force to damage the boot clamp. This will result in a loss of grease from the outer CV joint. Place a block of wood, or similar item, between the lower arm and the outer CV joint to prevent the lower arm from striking the outer CV joint.
NOTE: Once pressure is applied to the ball joint with the Ball Joint Separator and Adapter, it may be necessary to tap the wheel knuckle at the ball joint area to separate the ball joint from the wheel knuckle.
28. Using the Ball Joint Separator and Adapter, separate the 2 lower ball joints from the wheel knuckle and remove the wheel knuckle.
Fig 23: Identifying Special Tool 204-592/1 And 204-592
Courtesy of FORD MOTOR CO.
29. Remove the bolt connecting the RH damper fork to the lower control arm.
Fig 24: Locating Damper Fork Bolt
Courtesy of FORD MOTOR CO.
30. Remove the 2 engine roll restrictor bracket bolts.
Fig 25: Locating Engine Roll Restrictor Bracket Bolts
Courtesy of FORD MOTOR CO.
31. Remove the bolts and position the power steering cooler tube aside.
Fig 26: Locating Power Steering Cooler Tube Bolts
Courtesy of FORD MOTOR CO.
32. Remove the 3 steering gear bolts and position the steering gear aside with mechanic's wire.
Fig 27: Locating Steering Gear Bolts
Courtesy of FORD MOTOR CO.
33. Position a suitable powertrain lift table under the subframe.
34. Remove the 2 rear subframe nuts.
Fig 28: Locating Rear Subframe Nuts
Courtesy of FORD MOTOR CO.
35. Remove the 4 bolts and the 2 subframe support brackets.
Fig 29: Locating Subframe Support Brackets And Bolts
Courtesy of FORD MOTOR CO.
NOTE: LH shown, RH similar.
36. Remove the 2 front subframe nuts and remove the subframe.
Fig 30: Locating Front Subframe Nuts
Courtesy of FORD MOTOR CO.

Front Wheel Drive (FWD) vehicles 

37. Remove the 2 catalytic converter bracket bolts.
Fig 31: Identifying Catalytic Converter Bracket Bolts
Courtesy of FORD MOTOR CO.
38. Remove the 2 nuts and remove the catalytic converter support bracket.
Fig 32: Identifying Catalytic Converter Support Bracket & Nuts
Courtesy of FORD MOTOR CO.
39. Remove the 3 bolts and position the RH halfshaft aside.
Fig 33: Identifying Intermediate Shaft Bearing Support Bracket & Nuts
Courtesy of FORD MOTOR CO.

AWD vehicles 

40. Using the Front Wheel Hub Remover, press the halfshaft out of the wheel hub.
Fig 34: Separating Halfshaft From Wheel Hub Using Special Tool (205-D070)
Courtesy of FORD MOTOR CO.
41. Remove the 2 bolts and the RH halfshaft.
Fig 35: Locating RH Halfshaft Bearing Support Bracket Bolts
Courtesy of FORD MOTOR CO.
42. Index the driveshaft, remove the 4 bolts and position the driveshaft aside.
Fig 36: Identifying Drive Shaft Bolts
Courtesy of FORD MOTOR CO.
43. Disconnect the RH catalyst monitor electrical connector.
Fig 37: Locating RH Catalyst Monitor Electrical Connector
Courtesy of FORD MOTOR CO.
44. Remove the 2 catalytic converter bracket bolts.
Fig 38: Identifying Catalytic Converter Bracket Bolts
Courtesy of FORD MOTOR CO.
45. Remove the 4 nuts and the RH catalytic converter.
Fig 39: Locating RH Catalytic Converter Nuts
Courtesy of FORD MOTOR CO.
46. Remove the 5 bolts and the power transfer unit PTU support bracket.
Fig 40: Locating Power Transfer Unit (PTU) Support Bracket & Bolts
Courtesy of FORD MOTOR CO.
NOTE: A new halfshaft seal must be installed anytime the RH halfshaft is removed.
NOTE: The seal deflector will be damaged during removal. Be careful not to damage the cover seal directly behind the seal deflector.
47. Remove the seal deflector.
Fig 41: Identifying Seal Deflector
Courtesy of FORD MOTOR CO.
48. Using the Bearing Cup Puller and Slide Hammer, remove the halfshaft seal from the PTU.
Fig 42: Removing Intermediate Shaft Seal Using Special Tools (100-001) & (308-047)
Courtesy of FORD MOTOR CO.
49. Remove the 5 bolts and the PTU.
Fig 43: Locating PTU Bolts
Courtesy of FORD MOTOR CO.

All vehicles 

50. Remove the 2 fasteners and the inspection cover.
Fig 44: Identifying Inspection Cover & Fasteners
Courtesy of FORD MOTOR CO.
51. Remove and discard the 4 torque converter nuts.
Fig 45: Identifying Torque Converter Nuts
Courtesy of FORD MOTOR CO.
52. Disconnect the transmission fluid cooler hoses from the transmission fluid cooler tubes.
Fig 46: Locating Transmission Fluid Cooler Hoses
Courtesy of FORD MOTOR CO.
53. Position a suitable high-lift transmission jack under the transaxle.
54. Remove the 7 torque converter housing bolts and remove the transaxle.
Fig 47: Locating Transaxle-To-Engine Bolts
Courtesy of FORD MOTOR CO.
55. If installing a new transaxle, the transmission fluid cooler will need to be backflushed and cleaned. Carry out transmission fluid cooler tube backflushing and cleaning. For additional information, refer to Transmission Fluid Cooler - Backflushing and Cleaning .