Automatic Transmission: Removal: Transaxle: Removal

All vehicles 

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
2. Disconnect the Mass Air Flow (MAF) sensor electrical connector.
   Fig 1: Locating Mass Air Flow (MAF) Sensor Electrical Connector

   Courtesy of FORD MOTOR CO.
3. Disconnect the engine breather from the Air Cleaner (ACL) assembly.
   Fig 2: Locating Engine Breather

   Courtesy of FORD MOTOR CO.
4. Remove the ACL  assembly bracket bolts.
   Fig 3: Locating ACL Assembly Bracket Bolts

   Courtesy of FORD MOTOR CO.
5. Disconnect the brake booster vacuum hose from the ACL  outlet pipe.
   Fig 4: Locating Brake Booster Vacuum Hose

   Courtesy of FORD MOTOR CO.
6. Loosen the ACL  outlet pipe clamp at the Throttle Body (TB) and remove the ACL  and ACL  outlet pipe assembly.
   Fig 5: Locating ACL Outlet Pipe Clamp

   Courtesy of FORD MOTOR CO.
7. Remove the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
8. Detach the wiring harness retainers from the battery tray.
   Fig 6: Locating Wiring Harness Retainers

   Courtesy of FORD MOTOR CO.
9. Remove the lower battery tray bracket bolts.
   Fig 7: Locating Lower Battery Tray Bracket Bolts

   Courtesy of FORD MOTOR CO.
10. Remove the upper battery tray bolt and nut and remove the battery tray and bracket.
    Fig 8: Locating Battery Tray Bolt And Nut

    Courtesy of FORD MOTOR CO.
11. Remove the upper intake manifold. For additional information, refer to ENGINE - 3.5L .
12. Disconnect the selector lever cable end from the manual control lever.
    Fig 9: Locating Selector Lever Cable End

    Courtesy of FORD MOTOR CO.
13. Remove the selector lever cable bracket bolts and position aside the selector lever cable and bracket.
    Fig 10: Locating Selector Lever Cable Bracket Bolts

    Courtesy of FORD MOTOR CO.
14. Remove the starter motor positive terminal cover.
    Fig 11: Locating Starter Motor Positive Terminal Cover

    Courtesy of FORD MOTOR CO.
15. Remove the starter terminals from the starter.
    Fig 12: Locating Starter Terminals

    Courtesy of FORD MOTOR CO.
16. Disconnect the wiring harness fastener from the starter motor studbolt.
    Fig 13: Locating Wiring Harness Fastener

    Courtesy of FORD MOTOR CO.
17. Remove the bolt, studbolt and the starter.
    Fig 14: Locating Bolt, Studbolt And Starter

    Courtesy of FORD MOTOR CO.
18. Disconnect the transaxle electrical connector and remove the wiring harness fastener from the main control cover stud.
    Fig 15: Locating Transaxle Electrical Connector

    Courtesy of FORD MOTOR CO.
19. Position the coolant hoses aside from the transmission fluid filler tube.
    Fig 16: Locating Coolant Hoses

    Courtesy of FORD MOTOR CO.
NOTE: Coolant hoses removed for clarity.
Fig 17: Locating Transmission Fluid Level Indicator
Courtesy of FORD MOTOR CO.
20. Remove the transmission fluid level indicator.
NOTE: Coolant hoses removed for clarity.
Fig 18: Locating Transmission Fluid Filler Tube
Courtesy of FORD MOTOR CO.
21. Remove the nut, rotate the transmission fluid filler tube counterclockwise 90 degrees and remove the transmission fluid filler tube.
22. Remove the top torque converter housing bolts.
    Fig 19: Locating Top Torque Converter Housing Bolts

    Courtesy of FORD MOTOR CO.
23. Install the Engine Lift Eye onto the LH cylinder head.
    Fig 20: Installing Engine Lift Eye Onto LH Cylinder Head

    Courtesy of FORD MOTOR CO.
24. Install the Engine Support Bar and Engine Spreader Bar to support the engine.
    Fig 21: Installing Engine Support Bar And Engine Spreader Bar To Support Engine

    Courtesy of FORD MOTOR CO.
25. Remove the front wheels. For additional information, refer to WHEELS & TIRES .
26. Remove the pushpin fasteners and the RH splash shield.
    Fig 22: Locating RH Splash Shield Pushpin Fasteners

    Courtesy of FORD MOTOR CO.
27. Remove the screws, pushpin fasteners and the front splash shield.
    Fig 23: Locating Front Splash Shield Screws And Pushpin Fasteners

    Courtesy of FORD MOTOR CO.
28. Remove the transmission fluid drain plug and allow the transmission fluid to drain.
    Fig 24: Locating Transmission Fluid Drain Plug

    Courtesy of FORD MOTOR CO.
29. Install the transmission fluid drain plug.
    • Tighten to 9 Nm (80 lb-in).
      Fig 25: Locating Transmission Fluid Drain Plug

      Courtesy of FORD MOTOR CO.
30. Remove the 3 power steering tube bracket bolts from the LH side of the subframe and position the power steering tube aside.
    Fig 26: Locating Power Steering Tube Bracket Bolt

    Courtesy of FORD MOTOR CO.
31. Remove the RH and LH front halfshafts. For additional information, refer to FRONT DRIVE HALFSHAFTS .
32. Inspect the halfshaft hub for wear or damage and install a new halfshaft, if necessary.
    1. Inspect the differential seal surface.
    2. Inspect the halfshaft bushing surface. If this surface is damaged, inspect the halfshaft bushing for damage.
    3. Inspect the differential side gear splines.
       Fig 27: Identifying Differential Seal Surface, Halfshaft Bushing Surface And Differential Side Gear Splines

       Courtesy of FORD MOTOR CO.
33. Remove the Y-pipe nuts and disconnect the exhaust hanger.
    • Discard the gasket and nuts.
      Fig 28: Locating Y-Pipe Nuts And Exhaust Hanger

      Courtesy of FORD MOTOR CO.
34. Remove the nuts and the Y-pipe assembly.
    • Discard the nuts.
      Fig 29: Locating Y-Pipe Assembly Nuts

      Courtesy of FORD MOTOR CO.
35. Remove and discard the nuts and bolts from the steering rack. Position the steering rack aside and support it using a suitable length of mechanic's wire.
    Fig 30: Locating Steering Rack Nuts And Bolts

    Courtesy of FORD MOTOR CO.
36. Remove and discard the sway bar bolts. Position the sway bar aside and support it using a suitable length of mechanic's wire.
    Fig 31: Locating Bar Bolts

    Courtesy of FORD MOTOR CO.
37. Remove the bolts from the roll restrictor bracket.
    Fig 32: Locating Roll Restrictor Bolts

    Courtesy of FORD MOTOR CO.

    All-Wheel Drive (AWD) vehicles 

38. Index-mark the driveshaft, remove and discard the driveshaft bolts. Position the driveshaft aside.
    Fig 33: Locating Driveshaft Bolts

    Courtesy of FORD MOTOR CO.
39. Disconnect the RH catalyst monitor electrical connector.
    Fig 34: Locating RH Catalyst Monitor Electrical Connector

    Courtesy of FORD MOTOR CO.
40. Remove the catalytic converter support bracket bolts.
    Fig 35: Locating Catalytic Converter Support Bracket Bolts

    Courtesy of FORD MOTOR CO.
41. Remove the 4 RH catalytic converter nuts and the RH catalytic converter.
    Fig 36: Locating RH Catalytic Converter Nuts

    Courtesy of FORD MOTOR CO.
42. Remove the bolts and the Power Transfer Unit (PTU) support bracket.
    Fig 37: Locating Power Transfer Unit (PTU) Support Bracket Bolts

    Courtesy of FORD MOTOR CO.
NOTE: The seal deflector will be damaged during removal. Be careful not to damage the cover seal directly behind the seal deflector.
NOTE: A new halfshaft seal must be installed anytime the RH halfshaft is removed.
43. Remove the intermediate shaft seal and seal deflector. For additional information, refer to TRANSFER CASE-POWER TRANSFER UNIT (PTU) .
44. Remove the PTU  bolts and the PTU  .
    Fig 38: Locating PTU Bolts

    Courtesy of FORD MOTOR CO.

    All vehicles 

45. Support the subframe using the Powertrain Lift.
    Fig 39: Supporting Subframe Using Powertrain Lift

    Courtesy of FORD MOTOR CO.
NOTE: RH shown in illustration, LH similar.
Fig 40: Locating Subframe Bracket Bolts
Courtesy of FORD MOTOR CO.
46. Remove the subframe bracket-to-body bolts.
NOTE: RH shown in illustration, LH similar.
Fig 41: Locating Rear Subframe Bolt
Courtesy of FORD MOTOR CO.
47. Remove the rear subframe bolts and the subframe brackets.
NOTE: RH shown in illustration, LH similar.
Fig 42: Locating Front Subframe Bolt
Courtesy of FORD MOTOR CO.
48. Remove the front subframe bolts.
49. Remove the subframe.
50. Remove the 2 fasteners and the torque converter inspection cover.
    Fig 43: Locating Torque Converter Inspection Cover

    Courtesy of FORD MOTOR CO.
51. Remove and discard the 3 torque converter bolts.
    Fig 44: Locating Torque Converter Bolt

    Courtesy of FORD MOTOR CO.
52. Remove the secondary latches from the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.
    Fig 45: Locating Secondary Latches

    Courtesy of FORD MOTOR CO.
53. Using the Transmission Cooler Line Disconnect Tool, disconnect the transmission fluid cooler tubes from the transmission fluid cooler thermal bypass valve.
    Fig 46: Disconnecting Transmission Fluid Cooler Tubes

    Courtesy of FORD MOTOR CO.
54. Remove the transaxle support insulator through bolt.
    1. Remove the flagnut.
    2. Release the tension from the through bolt to remove it from the transaxle mount.
       Fig 47: Identifying Transaxle Support Insulator Through Bolt

       Courtesy of FORD MOTOR CO.
55. Lower the transaxle from the mount about 50.8 mm (2 in).
56. Remove the nuts, the bolt and the transaxle support insulator bracket.
    Fig 48: Locating Transaxle Support Insulator Bracket Nuts And Bolt

    Courtesy of FORD MOTOR CO.
57. Using the Transmission Jack Adapter, support the transaxle.
    Fig 49: Supporting Transaxle

    Courtesy of FORD MOTOR CO.
58. Remove the remaining torque converter housing bolts and remove the transaxle from the vehicle.
    Fig 50: Locating Torque Converter Housing Bolts

    Courtesy of FORD MOTOR CO.
59. Remove the manual control lever.
    Fig 51: Locating Manual Control Lever With Bolts

    Courtesy of FORD MOTOR CO.
60. Remove and discard the transmission fluid cooler tube bolts.
    Fig 52: Locating Transmission Fluid Cooler Tube Bolts

    Courtesy of FORD MOTOR CO.
61. Remove the nuts, pull the transmission fluid cooler thermal bypass valve and the transmission fluid cooler tubes straight up and remove the assembly from the transaxle.
    Fig 53: Pulling Transmission Fluid Cooler Thermal Bypass Valve And Transmission Fluid Cooler Tubes

    Courtesy of FORD MOTOR CO.
62. Inspect the transaxle case to be sure that the transmission fluid cooler tube seals and backing rings were removed with the transmission fluid cooler tubes and are not stuck in the transaxle case. If the transmission fluid cooler tube seals or backing rings are stuck in the transaxle case, remove the seals and backing rings.
    Fig 54: Locating Transmission Fluid Cooler Tube Seals And Backing Rings

    Courtesy of FORD MOTOR CO.
63. If the transaxle is to be overhauled or if installing a new or re-manufactured transaxle, carry out transmission fluid cooler backflushing and cleaning. For additional information, refer to TRANSMISSION FLUID COOLER BACKFLUSHING AND CLEANING .