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Engine - Manual Transaxle

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Special Tools

Illustration Tool Name Tool Number
GF0017296
 Adapter for 204-592 204-592/1
GF0000536
 Heavy Duty Floor Crane 014-00071 or equivalent
GF0017081
 Powertrain Lift 014-00765
GF0019849
 Remover, Halfshaft 205-243 (Part of 205-241)
GF0019850
 Remover, Halfshaft 205-832
GF0010812
 Remover, Tie-Rod End 211-105
GF0017295
 Separator, Ball Joint 204-592
GF0000218
 Slide Hammer 100-001
GF0000267
 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
GF0024108
 Universal Adapter Brackets 014-0001
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. 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 AND LIFTING article.
  2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
  3. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
  4. Recover the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS article.
  5. Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent).
    • Using a suitable holding device, hold the steering wheel in the straight-ahead position.
    6. Fig 1: Holding Steering Wheel In Straight-Ahead Position Using A Suitable Holding Device
    GF0041294Courtesy of FORD MOTOR CO.
  6. Remove the 2 nuts and the steering joint cover.
    7. Fig 2: Locating Steering Joint Cover And Nuts
    GF0028747Courtesy of FORD MOTOR CO.
    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 article.
    NOTE: Index-mark the steering column shaft position to the steering gear for reference during installation.
  7. Remove the bolt and disconnect the steering column shaft from the steering gear.
    8. Fig 3: Locating Steering Column Shaft Index Mark And Bolt
    GF0028748Courtesy of FORD MOTOR CO.
  8. Remove the bolt and disconnect the Power Steering Pressure (PSP) tube from the power steering pump.
    • Route the PSP tube out the bottom of the engine compartment.
    9. Fig 4: Locating Power Steering Pressure (PSP) Tube Bolt
    GF0028749Courtesy of FORD MOTOR CO.
  9. Drain the cooling system. For additional information, refer to ENGINE COOLING article.
  10. If equipped, remove the 7 screws and the underbody cover.
    11. Fig 5: Locating Splash Shield Bolts
    GF0028704Courtesy of FORD MOTOR CO.
  11. Remove the exhaust flexible pipe. For additional information, refer to EXHAUST SYSTEM article.
    12. NOTE: The steering gear-to-dash seal must be removed or it will be damaged when lowering the subframe.
  12. Release the 4 clips and slide the steering gear-to-dash seal off of the steering gear and into the passenger compartment.
    13. Fig 6: Locating Steering Gear-To-Dash Seal Clips
    GF0028750Courtesy of FORD MOTOR CO.
  13. Remove the engine roll restrictor bolt.
    14. Fig 7: Locating Engine Roll Restrictor Bolt
    GF0028646Courtesy of FORD MOTOR CO.
  14. Remove the 4 screws and position the RH fender splash shield aside.
    15. Fig 8: Locating RH Fender Splash Shield Screws
    G04684102Courtesy of FORD MOTOR CO.
  15. Remove the 6 pin-type retainers (4 shown) and the RH splash shield.
    16. Fig 9: Locating Pin-Type Retainers & LH Splash Shield
    GF0041295Courtesy of FORD MOTOR CO.
  16. Remove the 4 screws and position the LH fender splash shield aside.
    17. Fig 10: Locating LH Fender Splash Shield Screws
    GF0028647Courtesy of FORD MOTOR CO.
  17. Remove the 6 pin-type retainers (4 shown) and the LH splash shield.
    18. Fig 11: Locating LH Splash Shield And Pin-Type Retainers
    GF0028648Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  18. Remove the cotter pins and nuts from the tie-rod ends.
    19. Fig 12: Locating Tie-Rod Ends Nuts And Cotter Pin
    GF0028751Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  19. Using the Tie-Rod End Remover, separate the tie-rod ends from the steering knuckles.
    20. Fig 13: Separating Tie-Rod Ends From Wheel Knuckles Using Special Tool (211-105)
    GF0028752Courtesy of FORD MOTOR CO.
  20. Disconnect the power steering cooler tube.
    21. Fig 14: Locating Power Steering Cooler Tube
    GF0028753Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  21. Remove the nuts and separate the sway bar links from the struts.
    22. Fig 15: Locating Stabilizer Bar Links Nut
    GF0028754Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  22. Remove the lower ball joint nuts.
    23. Fig 16: Locating Lower Ball Joint Nuts
    GF0028653Courtesy 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 special tool, it may be necessary to tap the wheel knuckle at the ball joint area to separate the ball joint from the wheel knuckle.
    NOTE: LH shown, RH similar.
  23. Using the Ball Joint Separator and Adapter, separate the lower ball joints from the lower control arms.
    24. Fig 17: Identifying Special Tools (204-592/1, 204-592)
    GF0028654Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  24. Remove the through bolts from the lower control arms.
    25. Fig 18: Locating Lower Control Arms Through Bolt
    GF0028655Courtesy of FORD MOTOR CO.
  25. Position the Powertrain Lift under the subframe assembly.
    26. Fig 19: Positioning Special Tool (014-00765) Under Subframe Assembly
    GF0028656Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  26. Remove the subframe bracket-to-body bolts.
    27. Fig 20: Locating Subframe Bracket-To-Body Bolts
    GF0028658Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  27. Remove the rear subframe nuts and the subframe brackets.
    28. Fig 21: Locating Subframe Nuts
    GF0028657Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  28. Remove the front subframe nuts.
    29. Fig 22: Locating Front Subframe Nuts
    GF0028659Courtesy of FORD MOTOR CO.
  29. Lower the subframe assembly from the vehicle.
  30. Remove the engine oil pan drain plug and drain the engine oil.
    • Install the drain plug and tighten to 28 Nm (21 lb-ft).
    31. Fig 23: Locating Engine Oil Pan Drain Plug
    GF0017104Courtesy of FORD MOTOR CO.
  31. Remove the oil filter element. For additional information, refer to Engine Lubrication Components - Exploded View  and Oil Filter Element .
  32. Remove the bolt, 2 nuts and the generator air inlet duct.
    33. Fig 24: Locating Generator Air Inlet Duct, Bolt And Nuts
    GF0028700Courtesy of FORD MOTOR CO.
  33. Remove the engine air cleaner and air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - 2.3L article.
  34. Remove the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
  35. Remove the nut and disconnect the wire from the battery cable.
    36. Fig 25: Locating Battery Cable And Nut
    GF0028755Courtesy of FORD MOTOR CO.
  36. Disconnect the 2 engine wiring harness electrical connectors.
    37. Fig 26: Locating Engine Wiring Harness Electrical Connectors
    GF0028756Courtesy of FORD MOTOR CO.
  37. Remove the bolt and the ground wire.
    38. Fig 27: Locating Ground Wire And Bolt
    GF0028757Courtesy of FORD MOTOR CO.
  38. Disconnect the PCM electrical connector and pin-type retainer.
    39. Fig 28: Locating Powertrain Control Module (PCM) Electrical Connector And Pin-Type Retainer
    GF0028758Courtesy of FORD MOTOR CO.
  39. Disconnect the fuel supply tube from the fuel rail. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
  40. Disconnect the crankcase vent tube from the valve cover.
    41. Fig 29: Locating Crankcase Vent Tube
    GF0028759Courtesy of FORD MOTOR CO.
  41. Depress the locking ring and disconnect the brake booster vacuum supply tube from the intake manifold.
    42. Fig 30: Locating Locking Ring And Brake Booster Vacuum Supply Tube
    GF0028701Courtesy of FORD MOTOR CO.
  42. Disconnect the Evaporative Emission (EVAP) tube from the intake manifold.
    43. Fig 31: Locating Evaporative Emissions (EVAP) Tube From Intake Manifold
    GF0028760Courtesy of FORD MOTOR CO.
  43. Detach the retaining clip and position the EVAP tube bundle aside.
    44. Fig 32: Locating Evaporative Emissions (EVAP) Tube Bundle Retaining Clip
    GF0028739Courtesy of FORD MOTOR CO.
  44. Disconnect the upper radiator and heater hoses from the coolant bypass.
    45. Fig 33: Locating Upper Radiator & Heater Hoses From Coolant Bypass
    GF0041296Courtesy of FORD MOTOR CO.
  45. If equipped, disconnect the block heater electrical connector and detach the harness retaining clips from the heater hose.
    46. Fig 34: Locating Block Heater Electrical Connector Harness Retaining Clips
    GF0028762Courtesy of FORD MOTOR CO.
  46. Disconnect the heater hose in-line connector.
    47. Fig 35: Locating Heater Hose Inline Connector
    GF0028763Courtesy of FORD MOTOR CO.
  47. Remove the 2 clutch tube bracket bolts.
    48. Fig 36: Locating Clutch Tube Bracket Bolts
    GF0028794Courtesy of FORD MOTOR CO.
  48. Remove the 2 bolts and position the clutch slave cylinder aside.
    49. Fig 37: Locating Clutch Slave Cylinder Bolts
    GF0028795Courtesy of FORD MOTOR CO.
  49. Disconnect the transaxle control cables from the control levers.
    • Detach the control cables from the bracket.
    50. Fig 38: Locating Control Cables
    GF0028796Courtesy of FORD MOTOR CO.
  50. Disconnect the power steering cooler tube.
    51. Fig 39: Locating Power Steering Cooler Tube
    GF0028768Courtesy of FORD MOTOR CO.
  51. Remove the bolt and position the radio frequency interference capacitor and ground wire aside.
    52. Fig 40: Locating Radio Frequency Interference Capacitor, Ground Wire And Bolt
    GF0028766Courtesy of FORD MOTOR CO.
  52. Detach the coolant vent hose retaining clip from the A/C tube.
    53. Fig 41: Locating Coolant Vent Hose Retaining Clip
    GF0028767Courtesy of FORD MOTOR CO.
  53. Remove the 2 A/C tube bracket bolts.
    54. Fig 42: Locating A/C Tube Bracket Bolts
    GF0028769Courtesy of FORD MOTOR CO.
  54. Remove the 2 nuts and disconnect the A/C tubes.
    55. Fig 43: Locating A/C Tubes Nuts
    GF0028770Courtesy of FORD MOTOR CO.
  55. Remove the nut and disconnect the A/C tube from the condenser.
    56. Fig 44: Locating A/C Tube To Condenser Nut
    GF0028771Courtesy of FORD MOTOR CO.
  56. Remove the bolt and the radio frequency interference capacitor from the engine mount bracket.
    57. Fig 45: Locating Radio Frequency Interference Capacitor Bolt
    GF0028772Courtesy of FORD MOTOR CO.
  57. Remove the retaining clip and disconnect the lower radiator hose.
    58. Fig 46: Removing Retaining Clip And Locating Lower Radiator Hose
    GF0028773Courtesy of FORD MOTOR CO.
  58. Using the Halfshaft Removers and Slide Hammer, separate the LH halfshaft from the transaxle and support the halfshaft with a length of mechanic's wire.
    59. Fig 47: Identifying Special Tools (100-001, 205-243 And 205-832)
    GF0028797Courtesy of FORD MOTOR CO.
  59. Remove the 2 RH halfshaft carrier bearing bracket bolts.
    60. Fig 48: Locating RH Halfshaft Carrier Bearing Bracket Bolts
    GF0028774Courtesy of FORD MOTOR CO.
  60. Separate the RH halfshaft from the transaxle and support the halfshaft with a length of mechanic's wire.
    61. Fig 49: Locating RH Halfshaft
    GF0028775Courtesy of FORD MOTOR CO.
  61. Remove the bellhousing-to-oil pan bolt.
    62. Fig 50: Locating Bellhousing-To-Oil Pan Bolt
    GF0028776Courtesy of FORD MOTOR CO.
  62. Remove the 2 oil pan-to-bellhousing bolts.
    63. Fig 51: Locating Oil Pan-To-Bellhousing Bolts
    GF0028777Courtesy of FORD MOTOR CO.
    NOTE: Position a suitable block of wood under the transaxle.
  63. Install the Powertrain Lift and Universal Adapter Brackets onto the engine.
    • Raise the engine and transaxle 25.4 mm (1 in) to neutralize the engine and transaxle mounts.
    64. Fig 52: Identifying Special Tools (014-0001, 014-00765)
    GF0028780Courtesy of FORD MOTOR CO.
  64. Remove the 2 transaxle mount bolts.
    65. Fig 53: Locating Transaxle Mount Bolts
    GF0028781Courtesy of FORD MOTOR CO.
  65. Remove the bolt, 2 nuts and the motor mount bracket.
    66. Fig 54: Locating Engine Mount Bracket Bolt And Nuts
    GF0028782Courtesy of FORD MOTOR CO.
  66. Lower the engine and transaxle from the vehicle.
  67. Remove the 2 nuts and disconnect the starter wires.
    68. Fig 55: Locating Starter Wire Nuts
    GF0028783Courtesy of FORD MOTOR CO.
  68. Detach the 2 wiring harness retainers from the starter stud bolts.
  69. Remove the 2 bolts and the starter.
    70. Fig 56: Locating Starter And Stud Bolts
    GF0028784Courtesy of FORD MOTOR CO.
  70. Remove the bolt and transaxle ground wire.
    71. Fig 57: Locating Ground Wire Bolt
    GF0028786Courtesy of FORD MOTOR CO.
  71. Remove the nut and position the engine wiring harness bracket aside.
    72. Fig 58: Locating Engine Wiring Harness Bracket And Nut
    GF0028787Courtesy of FORD MOTOR CO.
  72. Disconnect the backup lamp electrical connector.
    73. Fig 59: Locating Backup Lamp Electrical Connector
    GF0028798Courtesy of FORD MOTOR CO.
  73. Disconnect the Vehicle Speed Sensor (VSS) electrical connector.
    74. Fig 60: Locating Vehicle Speed Sensor (VSS) Electrical Connector
    GF0028799Courtesy of FORD MOTOR CO.
  74. Install the Heavy Duty Floor Crane and Spreader Bar and remove the engine and transaxle from the Powertrain Lift table.
    75. Fig 61: Identifying Special Tools (014-00071, 303-D089)
    GF0028793Courtesy of FORD MOTOR CO.
  75. Remove the bellhousing-to-engine retainers.
    • Separate the engine and transaxle.
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