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In-Vehicle Crossbeam: Installation

WARNING: This page is about a different car, the 2005 Mercury Montego, 2005 Ford Freestyle, and 2005 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.

    All vehicles 

  1. If installing a new in-vehicle crossbeam, install the heater core and evaporator core housing. For additional information, refer to HEATING & VENTILATION .
    2. CAUTION: To avoid injury or damage to the crossbeam, the help of an assistant is required to carry out this step.
    NOTE: Install a bolt on each side and finger tighten to support the crossbeam, then install the remaining bolts.
  2. Using the previously marked alignment points, position the crossbeam and install the 6 tunnel reinforcement bolts.
    • Tighten to 25 Nm (18 lb-ft).
  3. Make sure the large RCM electrical connector position assurance lever is in the full RELEASE position before attempting to connect the connector.
    Fig 1: Positioning Large RCM Electrical Connector Lever
    G03989195Courtesy of FORD MOTOR CO.
    4. CAUTION: Placing the large RCM electrical wiring connector into the RCM at an angle can cause bad connections and damage components.
  4. Position the large RCM electrical wiring connector into the RCM.
      CAUTION: Do not push the connector to where the lever pivots and seats itself. Light pressure is needed to get the connector into position on the RCM before using the lever to fully seat the connector.
      Fig 2: Aligning Large RCM Electrical Wiring Connector To RCM
      G03989196Courtesy of FORD MOTOR CO.
    • With the large RCM electrical wiring connector uniformly aligned to the RCM, lightly push in until a subtle audible click is heard and a slight resistance is felt.
  5. Connect the large RCM electrical wiring connector.
    • Using the connector position assurance lever, pivot it toward the RCM, drawing the connector into the RCM.
    • Make sure the thumb tab is engaged to the retainer on the RCM and locked in place.
      Fig 3: Connecting Large RCM Electrical Wiring Connector
      G03989197Courtesy of FORD MOTOR CO.

    6. Freestyle 

  6. Install the A/C floor duct.
    Fig 4: Installing/C Floor Duct
    G03989193Courtesy of FORD MOTOR CO.

    7. All vehicles 

    NOTE: Freestyle shown; Five Hundred, Montego similar.
  7. Install the steering column pinch bolt.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 5: Installing Steering Column Pinch Bolt
      G03989192Courtesy of FORD MOTOR CO.
  8. Install the RH instrument panel cowl top bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 6: Installing RH Instrument Panel Cowl Top Bolts
      G03989191Courtesy of FORD MOTOR CO.
  9. Install the LH instrument panel cowl top bolt.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 7: Installing LH Instrument Panel Cowl Top Bolt
      G03989190Courtesy of FORD MOTOR CO.
    10. NOTE: LH side shown; RH side similar.
  10. Install the transaxle roll restrictor bar bolts.
    • Tighten to 55 Nm (40 lb-ft).
      Fig 8: Identifying Transaxle Roll Restrictor Bar Bolts
      G03989189Courtesy of FORD MOTOR CO.
  11. Install the transaxle roll restrictor bolt.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 9: Locating Upper Roll Restrictor Bolt
      G03989188Courtesy of FORD MOTOR CO.
  12. Install the PCM. For additional information, refer to ELECTRONIC ENGINE CONTROLS .
  13. Install the TXV manifold bolt.
    • Install the new O-ring seals.
    • Tighten to 8 Nm (71 lb-in).
  14. Connect the heater hoses.
    Fig 10: Connecting Heater Hoses
    G03989187Courtesy of FORD MOTOR CO.
  15. Fill the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
  16. If a new in-vehicle crossbeam was installed, a Radio Spacer Kit (6F93-18N800-AA) must be installed prior to the installation of the radio.
    • Prior to installing the radio into the instrument panel assembly, clean the instrument panel radio attachments surfaces of any loose dust, dirt or debris.
    • Apply a general adhesive on one side of the spacer and attach to the instrument panel radio surface. Repeat for all 4 places on the instrument panel radio attachment surfaces.
    • Install the radio using the new fasteners and tighten to 3 Nm (26 lb-in).
  17. Install the instrument panel upper section. For additional information, refer to INSTRUMENT PANEL UPPER SECTION .
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