LEMON Manuals: Even more car manuals for everyone
Home >> Mercury >> 2010 >> Milan Base, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 549 (Automatic Transmission - CVT) >> Removal >> Transaxle - All Wheel Drive (AWD) >> Removal

Transaxle - All Wheel Drive (AWD): Removal

WARNING: This page is about a different car, the 2006 Mercury Montego, 2006 Ford Freestyle, and 2006 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Remove the battery and battery tray. For additional information, refer to REMOVAL AND INSTALLATION .
  3. Remove the air cleaner and the outlet pipe. For additional information, refer to REMOVAL AND INSTALLATION .
  4. Remove the cowl panel grille. For additional information, refer to REMOVAL AND INSTALLATION .
  5. Remove the upper roll restrictor bolt.
    Fig 1: Locating Upper Roll Restrictor Bolt
    G04656433Courtesy of FORD MOTOR CO.
  6. Remove the 4 roll restrictor brace bolts and remove the roll restrictor brace.
    Fig 2: Locating Roll Restrictor Brace Bolts
    G04656434Courtesy of FORD MOTOR CO.
  7. Disconnect the shift cable end.
    Fig 3: Locating Shift Cable End
    G04656435Courtesy of FORD MOTOR CO.
  8. Remove the electrical connector from the shift cable bracket.
    Fig 4: Locating Electrical Connector
    G04656436Courtesy of FORD MOTOR CO.
  9. Remove the 2 bolts for the shift cable bracket and position the cable and bracket aside.
    Fig 5: Locating Shift Cable Bracket Bolts
    G04656437Courtesy of FORD MOTOR CO.
  10. Disconnect the wire harness from the transaxle.
    Fig 6: Locating Wire Harness
    G04656438Courtesy of FORD MOTOR CO.
  11. If equipped, remove the auxiliary coolant flow pump assembly.
    1. Disconnect the electrical connector.
    2. Remove the bolts and position the pump assembly aside.
    Fig 7: Identifying Auxiliary Coolant Flow Pump Assembly
    G04656439Courtesy of FORD MOTOR CO.
  12. Disconnect the lower wire harness from the transaxle.
    Fig 8: Locating Lower Wire Harness
    G04656440Courtesy of FORD MOTOR CO.
  13. Remove the 4 bolts for the roll restrictor bracket and remove the bracket.
    Fig 9: Locating Roll Restrictor Bracket Bolts
    G04656441Courtesy of FORD MOTOR CO.
  14. Disconnect the wire harness from the roll restrictor, remove the 2 bolts and remove the roll restrictor.
    Fig 10: Locating Roll Restrictor Bolts
    G04656442Courtesy of FORD MOTOR CO.
  15. Remove the positive crankcase ventilation (PCV) hose.
    Fig 11: Locating Positive Crankcase Ventilation (PCV) Hose
    G04656443Courtesy of FORD MOTOR CO.
  16. Disconnect the vacuum hoses from the throttle body.
    Fig 12: Locating Vacuum Hoses
    G04656444Courtesy of FORD MOTOR CO.
  17. Remove the bolt for the power steering line bracket and position it aside.
    Fig 13: Locating Power Steering Line Bracket Bolt
    G04656445Courtesy of FORD MOTOR CO.
  18. Remove the plastic electrical cover for the starter motor electrical connectors.
    Fig 14: Locating Plastic Electrical Cover
    G04656446Courtesy of FORD MOTOR CO.
  19. Disconnect the 2 starter motor electrical connectors.
    Fig 15: Locating Starter Motor Electrical Connectors
    G04656447Courtesy of FORD MOTOR CO.
  20. Remove the 2 bolts for the starter and remove the starter.
    Fig 16: Locating Starter Bolts
    G04656448Courtesy of FORD MOTOR CO.
  21. Remove the fluid cooler tube bracket from the transaxle.
    Fig 17: Locating Fluid Cooler Tube Bracket
    G04656449Courtesy of FORD MOTOR CO.
  22. Disconnect the ground wire.
    Fig 18: Locating Ground Wire
    G04656450Courtesy of FORD MOTOR CO.
    23. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
    Fig 19: Locating Electrical Connector
    G04656451Courtesy of FORD MOTOR CO.
  23. Disconnect the transaxle bulkhead electrical connector.
    • Rotate the electrical connector counterclockwise to disconnect.
  24. Disconnect the wire harness from the transaxle.
    Fig 20: Locating Wire Harness
    G04656452Courtesy of FORD MOTOR CO.
  25. Remove the 4 upper transaxle bolts.
    Fig 21: Locating Upper Transaxle Bolts
    G04656453Courtesy of FORD MOTOR CO.
  26. If a transaxle exchange or overhaul is required, the transmission fluid must be drained.
    • Remove the drain plug and allow the fluid to drain.
    Fig 22: Locating Drain Plug
    G04656454Courtesy of FORD MOTOR CO.
  27. Remove the LH and RH halfshafts. For additional information, refer to REMOVAL - LH and REMOVAL - RH .
  28. If removed, install the drain plug.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 23: Locating Drain Plug
    G04656455Courtesy of FORD MOTOR CO.
  29. Remove and discard the 2 nuts for the front exhaust pipe.
    Fig 24: Locating Front Exhaust Pipe Nuts
    G04656456Courtesy of FORD MOTOR CO.
  30. Remove and discard the 2 nuts for the rear exhaust pipe.
    Fig 25: Locating Rear Exhaust Pipe Nuts
    G04656457Courtesy of FORD MOTOR CO.
  31. Remove and discard the 2 nuts for the catalytic converter pipe, disconnect the rubber hanger and remove the pipe.
    Fig 26: Locating Catalytic Converter Pipe Nuts
    G04656458Courtesy of FORD MOTOR CO.
  32. Remove the 2 outer bolts for the driveshaft brace.
    Fig 27: Locating Driveshaft Brace Bolts
    G04656459Courtesy of FORD MOTOR CO.
    33. NOTE:
    1. Index-mark the rear driveshaft flange to the power transfer unit (PTU).
    2. The driveshaft flange can stay in the PTU flange. It does not need to be positioned aside at this time.
    Fig 28: Locating Front Driveshaft Flange Bolts
    G04656460Courtesy of FORD MOTOR CO.
  33. Remove and discard the 6 bolts from the front driveshaft flange.
  34. Remove the upper PTU bracket bolts and the bracket.
    Fig 29: Locating Upper PTU Bracket Bolts
    G04656461Courtesy of FORD MOTOR CO.
  35. Remove the 4 bolts for the PTU and remove the PTU.
    Fig 30: Locating PTU Bolts
    G04656462Courtesy of FORD MOTOR CO.
  36. Using mechanic's wire, position the rear driveshaft aside.
  37. If equipped, disconnect the engine block heater electrical connector.
    Fig 31: Locating Engine Block Heater Electrical Connector
    G04656463Courtesy of FORD MOTOR CO.
  38. Position the heat shield for the knock sensor aside.
    Fig 32: Locating Knock Sensor
    G04656464Courtesy of FORD MOTOR CO.
  39. Remove the bolt and remove the knock sensor.
    Fig 33: Locating Knock Sensor Bolt
    G04656465Courtesy of FORD MOTOR CO.
  40. Disconnect the knock sensor wire harness from the transaxle.
    Fig 34: Locating Knock Sensor Wire Harness
    G04656466Courtesy of FORD MOTOR CO.
  41. Remove the transaxle-to-engine bolt.
    Fig 35: Locating Transaxle-To-Engine Bolt
    G04656467Courtesy of FORD MOTOR CO.
  42. Remove the bolt for the power steering hose.
    Fig 36: Locating Power Steering Hose Bolt
    G04656468Courtesy of FORD MOTOR CO.
    43. NOTE: When installing the lifting bracket it will be easier to loosely install the upper bolt first, then install the lower bolt.
    Fig 37: Locating Lower Half Of Lifting Hook (303-1140)
    G04656469Courtesy of FORD MOTOR CO.
  43. Install the lower half of the lifting hook.
  44. Install the upper half of the lifting hook.
    Fig 38: Locating Upper Half Of Lifting Hook (303-1140)
    G04656470Courtesy of FORD MOTOR CO.
  45. Disconnect the vapor tube from the canister purge valve.
    Fig 39: Locating Vapor Tube
    G04656471Courtesy of FORD MOTOR CO.
  46. Remove the bolt for the power steering hose.
    Fig 40: Locating Power Steering Hose Bolt
    G04656472Courtesy of FORD MOTOR CO.
  47. Install the special tool to the RH cylinder head.
    Fig 41: Identifying Special Tool (134-00243)
    G04656473Courtesy of FORD MOTOR CO.
  48. Remove and discard the 2 bolts for the catalytic converter.
    Fig 42: Locating Catalytic Converter Bolts
    G04656474Courtesy of FORD MOTOR CO.
  49. Install the special tool to the LH cylinder head.
    Fig 43: Identifying Special Tool (134-00243)
    G04656475Courtesy of FORD MOTOR CO.
  50. Install the special tools to support the engine assembly.
    Fig 44: Identifying Special Tools (303-290-01, 303-290A, 303-290A-03A, 303-290A-12)
    G04656476Courtesy of FORD MOTOR CO.
  51. Install the special tools to the LH (front) cylinder head.
    Fig 45: Identifying Special Tools (134-00243, 303-290A-12)
    G04656477Courtesy of FORD MOTOR CO.
  52. Install the special tools to the RH (rear) cylinder head.
    Fig 46: Identifying Special Tools (134-00243, 303-290A-12)
    G04656478Courtesy of FORD MOTOR CO.
  53. Install the special tools into the lifting hook near the EGR valve.
    Fig 47: Identifying Special Tool (303-1140, 303-290A-12)
    G04656479Courtesy of FORD MOTOR CO.
  54. Disconnect the lower radiator hose from the retainers and position the hose aside.
    Fig 48: Locating Lower Radiator Hose
    G04656480Courtesy of FORD MOTOR CO.
  55. Remove the 4 bolts that hold the power steering line to the subframe.
    Fig 49: Locating Power Steering Line Bolt
    G04656481Courtesy of FORD MOTOR CO.
  56. Disconnect the wire harness from the LH front of the subframe.
    Fig 50: Locating Wire Harness
    G04656482Courtesy of FORD MOTOR CO.
  57. Remove the bolts and nuts for the power steering rack. Use mechanic's wire to hold the power steering rack up and position aside.
    Fig 51: Locating Power Steering Rack Bolt & Nut
    G04656483Courtesy of FORD MOTOR CO.
  58. Disconnect the HO2S electrical connector from the subframe.
    Fig 52: Locating HO2S Electrical Connector
    G04656484Courtesy of FORD MOTOR CO.
  59. Disconnect the 3 pushpins and position the splash shield aside.
    Fig 53: Locating Splash Shield Pushpins
    G04656485Courtesy of FORD MOTOR CO.
  60. Remove the nut for the front motor mount.
    Fig 54: Locating Front Motor Mount Nut
    G04656486Courtesy of FORD MOTOR CO.
  61. Remove the 2 bolts for the lower stabilizer mount.
    Fig 55: Locating Lower Stabilizer Mount Bolts
    G04656487Courtesy of FORD MOTOR CO.
  62. Remove the nut for the rear motor mount.
    Fig 56: Locating Rear Motor Mount Nut
    G04656488Courtesy of FORD MOTOR CO.
  63. Remove the bolts for the rear transaxle mount.
    Fig 57: Locating Rear Transaxle Mount Bolts
    G04656489Courtesy of FORD MOTOR CO.
  64. Remove the 2 bolts for the LH rear subframe mount.
    Fig 58: Locating LH Rear Subframe Mount Bolts
    G04656490Courtesy of FORD MOTOR CO.
  65. Remove the 2 bolts for the RH rear subframe mount.
    Fig 59: Locating RH Rear Subframe Mount Bolts
    G04656491Courtesy of FORD MOTOR CO.
  66. Remove and discard the LH and RH stabilizer bar link nuts and separate the stabilizer bar links from the struts.
    Fig 60: Locating Stabilizer Bar Link Nuts
    G04656492Courtesy of FORD MOTOR CO.
  67. Using a suitable powertrain lift, remove the 4 subframe bolts and remove the subframe.
    Fig 61: Locating Subframe Bolts
    G04656493Courtesy of FORD MOTOR CO.
  68. Disconnect the HO2S electrical connector.
    Fig 62: Locating HO2S Electrical Connector
    G04656494Courtesy of FORD MOTOR CO.
  69. Remove the bolt for the catalytic converter bracket and remove the catalytic converter.
    Fig 63: Locating Catalytic Converter Bracket Bolt
    G04656495Courtesy of FORD MOTOR CO.
  70. Remove the pin and remove the rubber access plug.
    Fig 64: Locating Rubber Access Plug
    G04656496Courtesy of FORD MOTOR CO.
  71. Remove and discard the 4 torque converter nuts.
    Fig 65: Locating Torque Converter Nuts
    G04656497Courtesy of FORD MOTOR CO.
    72. CAUTION: When disconnecting the fluid cooler tubes, pull straight up to prevent damage to the fluid cooler tubes.
    Fig 66: Locating Transmission Fluid Cooler Tubes
    G04656498Courtesy of FORD MOTOR CO.
  72. Disconnect the transmission fluid cooler tubes from the transaxle.
  73. Remove and discard the 4 transmission fluid cooler tube seals.
    Fig 67: Locating Transmission Fluid Cooler Tube Seals
    G04656499Courtesy of FORD MOTOR CO.
  74. Remove the transmission fluid cooler tube bracket bolts.
    Fig 68: Locating Transmission Fluid Cooler Tube Bracket Bolts
    G04656500Courtesy of FORD MOTOR CO.
    75. NOTE: Make sure the transmission is securely fastened to the transmission jack.
  75. Position a suitable high-lift transmission jack under the transmission.
  76. Remove the 3 transaxle-to-engine bolts.
    Fig 69: Locating Transaxle-To-Engine Bolts
    G04656501Courtesy of FORD MOTOR CO.
  77. Remove the transaxle from under the car.
  78. If the transaxle is to be overhauled or if installing a new transaxle, install a new transmission fluid cooler. For additional information, refer to REMOVAL AND INSTALLATION .
  79. If the transaxle is to be overhauled or if installing a new transaxle, carry out transmission backflushing and cleaning. For additional information, refer to TRANSMISSION FLUID COOLER TUBES - BACKFLUSHING AND CLEANING .
  80. If removing the transaxle for something other than a transaxle related repair, inspect the differential seals for damage or leaking. If leaking or damage is indicated, install new differential seals. For additional information, refer to DIFFERENTIAL SEALS - LH , DIFFERENTIAL SEALS - RH, ALL WHEEL DRIVE (AWD)  or DIFFERENTIAL SEALS - RH, FRONT WHEEL DRIVE (FWD) .
  81. If installing a new transaxle, remove the bolts and remove the rear transaxle support insulator.
    Fig 70: Locating Rear Transaxle Support Insulator Bolts
    G04656502Courtesy of FORD MOTOR CO.
  82. If installing a new transaxle, remove and discard the 4 retainers and remove the transaxle insulator.
    Fig 71: Locating Transaxle Insulator Bolts
    G04656503Courtesy of FORD MOTOR CO.
  83. If installing a new transaxle, remove the bolt and remove the fluid level indicator and tube.
    Fig 72: Locating Fluid Level Indicator & Tube Bolt
    G04656504Courtesy of FORD MOTOR CO.
scientia non olet · About LEMON Manuals