Transaxle - 3.0L

Illustration	Tool Name	Tool Number
	Adapter for 204-592	204-592/1
	Bearing Cup Puller	308-047 (T77F-1102-A)
	Engine Lifting Bracket Set	303-1140
	Lifting Bracket, Engine	303-050 (T70P-6000)
	Remover, Front Wheel Hub	205-D070 (D93P-1175-B) or equivalent
	Separator, Ball Joint	204-592
	Slide Hammer	100-001 (T50T-100-A)
	Socket, Exhaust Gas Oxygen Sensor	303-476 (T94P-9472-A)
	Support Bar, Engine	303-F072
	Universal Adapter Brackets	014-0001

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 - 2.3L article or INTAKE AIR DISTRIBUTION AND FILTERING - 3.0L (4V) article.
4. Disconnect the selector lever cable end.
Fig 1: Locating Selector Lever Cable End
Courtesy of FORD MOTOR CO.
5. Remove the 3 bolts for the selector lever cable bracket and position the cable and bracket aside.
Fig 2: Locating Transaxle Control Cable Bracket Bolts
Courtesy of FORD MOTOR CO.
6. Disconnect the wire harness from the Transmission Control Module (TCM).
Fig 3: Identifying Transmission Control Module Electrical Connector
Courtesy of FORD MOTOR CO.
7. Remove the 2 ground strap bolts and position aside the ground straps.
Fig 4: Identifying Ground Straps & Ground Strap Bolts
Courtesy of FORD MOTOR CO.
8. Remove the electrical terminal cover for the starter motor electrical connectors.
Fig 5: Identifying Electrical Cover For Starter Motor Electrical Connectors
Courtesy of FORD MOTOR CO.
9. Remove the starter terminals.
Fig 6: Identifying Starter Motor Electrical Connectors
Courtesy of FORD MOTOR CO.
10. Remove the 2 bolts and the starter.
Fig 7: Locating Starter Bolts
Courtesy of FORD MOTOR CO.
11. Remove the 3 upper torque converter housing bolts.
Fig 8: Locating Upper Torque Converter Housing Bolts
Courtesy of FORD MOTOR CO.
12. Disconnect the EGR valve electrical connector.
Fig 9: Locating EGR Valve Electrical Connector
Courtesy of FORD MOTOR CO.
13. Disconnect the EGR tube nut from the valve.
Fig 10: Locating EGR Tube Nut
Courtesy of FORD MOTOR CO.
14. Remove the 2 bolts and the EGR valve. Discard the gasket.
Fig 11: Locating EGR Valve And Bolts
Courtesy of FORD MOTOR CO.
15. Remove the bolt from the power steering line bracket and position it aside.
Fig 12: Locating Bracket For Power Steering Hose
Courtesy of FORD MOTOR CO.
16. 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.
17. 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.
18. 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.
19. 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.
NOTE: LH shown, RH similar.
20. Remove the 2 nuts and separate the sway bar links from the struts.
Fig 17: Locating Sway Bar Links Nut
Courtesy of FORD MOTOR CO.
21. If a transaxle exchange or overhaul is required, the transmission fluid must be drained.
    • Remove the transmission fluid drain plug and allow the transmission fluid to drain.
Fig 18: Identifying Transmission Drain Plug
Courtesy of FORD MOTOR CO.
22. If removed, install the transmission fluid drain plug.
    • Tighten to 47 Nm (35 lb-ft).
Fig 19: Identifying Transmission Drain Plug
Courtesy of FORD MOTOR CO.
23. Remove the LH halfshaft. For additional information, refer to FRONT DRIVE HALFSHAFTS article.

All-Wheel Drive (AWD) vehicles 

24. Remove and discard the front wheel hub nut.
Fig 20: Locating Front Wheel Hub Nut
Courtesy of FORD MOTOR CO.

All vehicles 

25. Remove the RH lower control arm nuts.
Fig 21: 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.
26. Using the Ball Joint Separator and Adapter, separate the 2 lower ball joints from the wheel knuckle and remove the wheel knuckle.
Fig 22: Identifying Special Tool 204-592/1 And 204-592
Courtesy of FORD MOTOR CO.
27. Remove the bolt connecting the RH damper fork to the lower control arm.
Fig 23: Locating Damper Fork Bolt
Courtesy of FORD MOTOR CO.
NOTE: Front Wheel Drive (FWD) shown, All-Wheel Drive (AWD) similar.
28. Remove the 2 Y-pipe bolts and nuts.
Fig 24: Locating Y-Pipe Bolts And Nuts
Courtesy of FORD MOTOR CO.
NOTE: FWD shown, AWD similar.
29. Remove the flexpipe nuts and the Y-pipe assembly.
Fig 25: Locating Flex Pipe Nuts
Courtesy of FORD MOTOR CO.
30. If equipped, remove the 2 bolts and the roll restrictor heat shield.
Fig 26: Locating Heat Shield And Bolts
Courtesy of FORD MOTOR CO.
NOTE: FWD shown, AWD similar.
31. Remove the 2 bolts from the engine roll restrictor bracket.
Fig 27: Locating Engine Roll Restrictor Bracket Bolts
Courtesy of FORD MOTOR CO.
32. Remove the bolts and position the power steering cooler tube aside.
Fig 28: Locating Power Steering Cooler Tube Bolts
Courtesy of FORD MOTOR CO.
33. Remove the 3 steering gear bolts and position the steering gear aside with mechanic's wire.
Fig 29: Locating Steering Gear Bolts
Courtesy of FORD MOTOR CO.
34. Position a suitable drivetrain lift table under the subframe.
35. Remove the 2 rear subframe nuts.
Fig 30: Locating Rear Subframe Nuts
Courtesy of FORD MOTOR CO.
36. Remove the 4 bolts and the 2 subframe support brackets.
Fig 31: Locating Subframe Support Brackets And Bolts
Courtesy of FORD MOTOR CO.
NOTE: LH shown, RH similar.
37. Remove the 2 front subframe nuts and remove the subframe.
Fig 32: Locating Front Subframe Nuts
Courtesy of FORD MOTOR CO.
NOTE: FWD shown, AWD similar.
38. Loosen the EGR tube nut at the RH exhaust manifold and remove the EGR tube.
Fig 33: Locating EGR Tube Nut At RH Exhaust Manifold
Courtesy of FORD MOTOR CO.

Front Wheel Drive (FWD) vehicles 

39. Remove the 2 bolts and the RH exhaust manifold heat shield.
Fig 34: Locating RH Exhaust Manifold Heat Shield And Bolts
Courtesy of FORD MOTOR CO.
40. Remove the 2 bolts and the catalytic converter band clamp.
Fig 35: Locating Catalytic Converter Band Clamp And Bolts
Courtesy of FORD MOTOR CO.
41. Remove the 2 bolts and the catalytic converter-to-engine block bracket.
Fig 36: Locating Catalytic Converter-To-Engine Block Bracket And Bolts
Courtesy of FORD MOTOR CO.
42. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector from the RH halfshaft bearing support bracket.
Fig 37: Locating Heated Oxygen Sensor (HO2S) Electrical Connector
Courtesy of FORD MOTOR CO.
43. Remove the bolt retaining the brake caliper hose.
Fig 38: Locating Brake Caliper Hose Bolt
Courtesy of FORD MOTOR CO.
44. Remove the 2 bolts and remove the RH halfshaft from the transaxle and position it aside with mechanic's wire.
Fig 39: Locating RH Halfshaft Carrier Bearing Bracket Bolts
Courtesy of FORD MOTOR CO.

AWD vehicles 

45. Using the Front Wheel Hub Remover, separate the halfshaft from the wheel hub.
Fig 40: Separating Halfshaft From Wheel Hub Using Special Tool (205-D070)
Courtesy of FORD MOTOR CO.
46. Remove the 2 bolts and the RH halfshaft.
Fig 41: Locating RH Halfshaft Bearing Support Bracket Bolts
Courtesy of FORD MOTOR CO.
47. Index the driveshaft, remove the 4 bolts from the driveshaft and position the driveshaft aside.
Fig 42: Identifying Drive Shaft Bolts
Courtesy of FORD MOTOR CO.
48. Disconnect the RH catalyst monitor sensor electrical connector and detach the wiring retainer.
Fig 43: Locating RH Catalyst Monitor Sensor Electrical Connector & Wiring Retainer
Courtesy of FORD MOTOR CO.
49. Using the Exhaust Gas Oxygen Sensor Socket, remove the RH catalyst monitor sensor.
Fig 44: Identifying RH Catalyst Monitor Sensor & Special Tool (303-476)
Courtesy of FORD MOTOR CO.
50. Disconnect the RH HO2S electrical connector.
Fig 45: Identifying RH HO2S Electrical Connector
Courtesy of FORD MOTOR CO.
51. Using the Exhaust Gas Oxygen Sensor Socket, remove the RH HO2S.
Fig 46: Identifying RH HO2S & Special Tool (303-476)
Courtesy of FORD MOTOR CO.
52. Remove the 6 bolts and the RH exhaust heat shield.
Fig 47: Locating RH Exhaust Heat Shield Bolts
Courtesy of FORD MOTOR CO.
53. Remove the 3 nuts and the catalytic converter band clamp RH half.
Fig 48: Locating RH Exhaust Heat Shield Bracket Nuts - Inboard Half
Courtesy of FORD MOTOR CO.
54. Remove the 2 bolts and the catalytic converter band clamp LH half.
Fig 49: Locating Catalytic Converter Band Clamp LH Half Nuts
Courtesy of FORD MOTOR CO.
55. Remove the nuts and the RH catalytic converter.
Fig 50: Locating RH Catalytic Converter Nuts
Courtesy of FORD MOTOR CO.
56. Remove the 5 bolts and the Power Transfer Unit (PTU) support bracket.
Fig 51: Identifying 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.
57. Remove the seal deflector.
Fig 52: Identifying Seal Deflector
Courtesy of FORD MOTOR CO.
58. Using the Bearing Cup Puller and Slide Hammer, remove the halfshaft seal from the PTU.
Fig 53: Removing Intermediate Shaft Seal Using Special Tools (100-001) & (308-047)
Courtesy of FORD MOTOR CO.
59. Remove the 5 bolts and the PTU.
Fig 54: Locating PTU Bolts
Courtesy of FORD MOTOR CO.

All vehicles 

NOTE: When installing the Engine Lifting Bracket Set, it will be easier to loosely install the upper bolt first, then install the lower bolt.
60. Install the lower half of the Engine Lifting Bracket Set.
Fig 55: Identifying Lower Half Of Lifting Hook
Courtesy of FORD MOTOR CO.
61. Install the upper half of the Engine Lifting Bracket Set.
Fig 56: Identifying Upper Half Of Lifting Hook
Courtesy of FORD MOTOR CO.
62. Install the Engine Lifting Bracket and Universal Adapter Bracket "L" hook on the LH side of the engine.
Fig 57: Identifying Universal Lifting Brackets
Courtesy of FORD MOTOR CO.
63. Install the Engine Support Bar to support the engine.
Fig 58: Installing Engine Support Bar To Support Engine
Courtesy of FORD MOTOR CO.
64. Remove the 2 bolts from the transmission insulator.
Fig 59: Locating Transaxle Insulator Bolts
Courtesy of FORD MOTOR CO.
65. Lower the transaxle and remove the 2 nuts and the bolt and remove the transaxle support insulator bracket.
Fig 60: Locating Transaxle Insulator Bracket Nuts And Bolt
Courtesy of FORD MOTOR CO.
66. Remove the HO2S bracket bolt and disconnect the wiring harness fastener.
Fig 61: Identifying Heated Oxygen Sensor (HO2S) Bracket & Stud Bolt
Courtesy of FORD MOTOR CO.
67. Remove the inspection cover.
Fig 62: Identifying Inspection Cover
Courtesy of FORD MOTOR CO.
68. Remove and discard the 3 torque converter nuts.
Fig 63: Locating Torque Converter Nuts
Courtesy of FORD MOTOR CO.
69. Disconnect the transmission fluid cooler hoses.
Fig 64: Locating Transmission Fluid Cooler Hoses
Courtesy of FORD MOTOR CO.
70. Position a suitable high-lift transmission jack under the transaxle.
71. Remove the 5 torque converter housing bolts and remove the transmission.
Fig 65: Locating Transaxle-To-Engine Bolts
Courtesy of FORD MOTOR CO.
72. If installing a new transaxle, the transmission fluid cooler will need to be backflushed and cleaned. Carry out transmission fluid cooler backflushing and cleaning. For additional information, refer to Transmission Fluid Cooler - Backflushing and Cleaning .