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In-Vehicle Crossbeam: Installation

  1. If installing a new in-vehicle crossbeam, install the heater core and evaporator core housing. For additional information, refer to AUXILIARY CLIMATE CONTROL article.
    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.
    4. Fig 1: View Of Connector Position Assurance Lever
    G03989905Courtesy of FORD MOTOR CO.
    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.
    • 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. Fig 2: Aligning Large RCM Electrical Wiring Connector To RCM
    GF0016584Courtesy of FORD MOTOR CO.
  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.
    6. Fig 3: Connecting Large RCM Electrical Wiring Connector
    GF0016585Courtesy of FORD MOTOR CO.
    NOTE: Freestyle shown; Five Hundred, Montego similar.
  6. Install the steering column pinch bolt.
    • Tighten to 25 Nm (18 lb-ft).
    7. Fig 4: Steering Column Pinch Bolt
    GF0016582Courtesy of FORD MOTOR CO.
  7. Install the RH instrument panel cowl top bolts.
    • Tighten to 25 Nm (18 lb-ft).
    8. Fig 5: RH Instrument Panel Cowl Top Bolts
    GF0016581Courtesy of FORD MOTOR CO.
  8. Install the LH instrument panel cowl top bolt.
    • Tighten to 25 Nm (18 lb-ft).
    9. Fig 6: LH Instrument Panel Cowl Top Bolt
    GF0016580Courtesy of FORD MOTOR CO.
  9. Install the TXV manifold bolt.
    • Install the new O-ring seals.
    • Tighten to 8 Nm (71 lb-in).
  10. Connect the heater hoses.
    11. Fig 7: Heater Hoses
    GF0016579Courtesy of FORD MOTOR CO.
  11. Install the PCM. For additional information, refer to ELECTRONIC ENGINE CONTROLS article.
    12. NOTE: LH side shown; RH side similar.
  12. Install the transaxle roll restrictor bar bolts.
    • Tighten to 55 Nm (41 lb-ft).
    13. Fig 8: Identifying Transaxle Roll Restrictor Bar Bolts
    G03989189Courtesy of FORD MOTOR CO.
  13. Install the transaxle roll restrictor bolt.
    • Tighten to 48 Nm (35 lb-ft).
    14. 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 ENGINE COOLING article.
  15. Fill the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS article.
  16. Install the instrument panel upper section. For additional information, refer to Instrument Panel Upper Section .
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