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In-Vehicle Crossbeam: Installation

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. If installing a new in-vehicle crossbeam, install the heater core and evaporator core housing. For additional information, refer to REMOVAL AND INSTALLATION .
    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 N.m (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: View Of Connector Position Assurance Lever
    G03989905Courtesy 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: Positioning Large RCM Electrical Wiring Connector Into RCM
      G04659011Courtesy 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
    G04659012Courtesy of FORD MOTOR CO.
  6. Install the steering column pinch bolt.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 4: Installing Steering Column Pinch Bolt (Freestyle Shown; Five Hundred, Montego Similar)
    G04659013Courtesy of FORD MOTOR CO.
  7. Install the RH instrument panel cowl top bolts.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 5: Installing RH Instrument Panel Cowl Top Bolts
    G04659014Courtesy of FORD MOTOR CO.
  8. Install the LH instrument panel cowl top bolt.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 6: Installing LH Instrument Panel Cowl Top Bolt
    G04659015Courtesy of FORD MOTOR CO.
  9. Install the TXV manifold bolt.
    • Install the new O-ring seals.
    • Tighten to 8 N.m (71 lb-in).
  10. Connect the heater hoses.
    Fig 7: Connecting Heater Hoses
    G04659016Courtesy of FORD MOTOR CO.
  11. Install the PCM. For additional information, refer to INSTALLATION .
    12. NOTE: LH side shown; RH side similar. Install the transaxle roll restrictor bar bolts.
    • Tighten to 55 N.m (41 lb-ft).
    Fig 8: Identifying Transaxle Roll Restrictor Bar Bolts
    G03989189Courtesy of FORD MOTOR CO.
  13. Install the transaxle roll restrictor bolt.
    • Tighten to 48 N.m (35 lb-ft).
    Fig 9: Locating Upper Roll Restrictor Bolt
    G03989188Courtesy of FORD MOTOR CO.
  14. Fill and bleed the engine cooling system. For additional information, refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
  15. Fill the A/C system. For additional information, refer to REFRIGERANT OIL ADDING .
  16. Install the instrument panel upper section. For additional information, refer to INSTRUMENT PANEL UPPER SECTION  .
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