Main Control Cover - 3.5L GTDI: Removal

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING article.
Remove the Air Cleaner (ACL) and outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION SYSTEM & INTAKE AIR FILTERING SYSTEM article.
Remove the brake booster vacuum tube from the LH turbocharger air inlet hose.

Fig 1: Locating Brake Booster Vacuum Tube
Courtesy of FORD MOTOR CO.
Remove the vacuum tube from the LH turbocharger air inlet hose.

Fig 2: Locating Vacuum Tube
Courtesy of FORD MOTOR CO.
Compress the constant tension clamp and remove the bypass hose from the LH turbocharger air inlet hose.

Fig 3: Locating Constant Tension Clamp
Courtesy of FORD MOTOR CO.
Disconnect the 2 quick connect couplings and remove the crankcase vent tube.

Fig 4: Locating Quick Connect Couplings And Crankcase Vent Tube
Courtesy of FORD MOTOR CO.
Loosen the 2 clamps and remove the LH turbo inlet tube.

Fig 5: Locating LH Turbo Inlet Tube Clamps
Courtesy of FORD MOTOR CO.
Remove the 4 retainers and the underbody shield.

Fig 6: Locating Retainers And Underbody Shield
Courtesy of FORD MOTOR CO.
Loosen the clamp and disconnect the LH turbocharger-to-Charge Air Cooler (CAC) hose from the turbocharger and position it.

Fig 7: Locating LH Turbocharger-To-Charge Air Cooler Hose Clamp
Courtesy of FORD MOTOR CO.
Remove the transmission fluid drain plug and allow the transmission fluid to drain.

Fig 8: Locating Transmission Fluid Drain Plug
Courtesy of FORD MOTOR CO.
Install the transmission fluid drain plug.
- Tighten to 9 Nm (80 lb-in).
  
  Fig 9: Locating Transmission Fluid Drain Plug
  Courtesy of FORD MOTOR CO.
Disconnect the transaxle electrical connector and remove the wiring harness fastener from the main control cover stud.

Fig 10: Locating Transaxle Electrical Connector And Wiring Harness Fastener
Courtesy of FORD MOTOR CO.
Remove the 2 nuts, pull the transmission fluid cooler thermal bypass valve off of the main control cover stud bolts and position it.

Fig 11: Locating Transmission Fluid Cooler Thermal Bypass Valve And Nuts
Courtesy of FORD MOTOR CO.

NOTE: Note the location of the stud bolts for assembly.

Fig 12: Locating Main Control Cover Mounting Bolts

Courtesy of FORD MOTOR CO.

Remove the 14 bolts and the main control cover.