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Section 1848 (Engine - 4.6L And 5.4L): Removal: Engine: Removal

WARNING: This page is about a different car, the 2008 Ford RV Cutaway, 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

All engines 

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING article.
  2. If equipped, recover the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS article.
  3. Remove the intake manifold. For additional information, refer to Intake Manifold - 4.6L  or Intake Manifold - 5.4L .
  4. Remove the starter. For additional information, refer to STARTING SYSTEM - GASOLINE ENGINES article.
  5. Remove the front bumper. For additional information, refer to BUMPERS article.
  6. Disconnect the lower radiator hose from the radiator.
    • Disconnect the hose hanger.
    • Disconnect the hose.
    7. Fig 1: Lower Radiator Hose And Retainers
    G03886599Courtesy of FORD MOTOR CO.
  7. Remove the push pin retainers and the splash shield.
    8. Fig 2: Identifying Push Pin Retainers And Splash Shield
    G03885266Courtesy of FORD MOTOR CO.
  8. Disconnect the transmission cooler hoses and drain the fluid into a suitable container.
    9. Fig 3: Identifying Transmission Cooler Hoses
    G03886172Courtesy of FORD MOTOR CO.
  9. Remove the 4 exhaust Y-pipe flange nuts.
    10. Fig 4: Locating Exhaust Manifold-To-Catalytic Converter Nuts
    GF0002678Courtesy of FORD MOTOR CO.
  10. Remove the oil drain plug and drain the engine oil.
    11. Fig 5: Engine Oil Drain Plug
    GF0002670Courtesy of FORD MOTOR CO.
  11. Disconnect the oil cooler hoses and set aside.
    12. Fig 6: Locating Oil Cooler Coolant Hoses
    G03885411Courtesy of FORD MOTOR CO.
  12. Remove and discard the oil filter.
    13. Fig 7: Locating Oil Filter
    G03885412Courtesy of FORD MOTOR CO.
    CAUTION: A new oil cooler must be installed or severe damage to the engine can occur.
    CAUTION: If metal or aluminum foreign material is present in the oil cooler, mechanical concerns exist. To diagnose mechanical concerns, refer to ENGINE SYSTEM - GENERAL INFORMATION article. Failure to follow this instruction may result in engine damage.
  13. Loosen the threaded insert and remove and discard the oil cooler.
    14. Fig 8: Identifying Oil Cooler
    G03885413Courtesy of FORD MOTOR CO.
  14. Remove the 2 bolts and the flexplate inspection cover.
    15. Fig 9: Locating Flexplate Inspection Cover Bolts
    GF0002672Courtesy of FORD MOTOR CO.
  15. Remove the cylinder block opening cover.
    16. Fig 10: Cylinder Block Opening Cover
    GF0011681Courtesy of FORD MOTOR CO.
  16. Remove the 4 nuts retaining the torque converter to the flexplate.
    • Rotate the crankshaft to access all of the torque converter nuts.
    • Discard the torque converter nuts.
    17. Fig 11: Locating Torque Converter-To-Flexplate Nuts
    GF0002674Courtesy of FORD MOTOR CO.
  17. Disconnect the shift cable and the mounting bracket.
    1. Disconnect the clip.
    2. Remove the bolts.
    18. Fig 12: Shift Cable & Mounting Bracket At Transmission
    GF0011682Courtesy of FORD MOTOR CO.
  18. Remove the 2 transmission-to-engine bolts and position the shifter cable support bracket, mounting bracket and cable aside.
    19. Fig 13: Transmission-To-Engine Bolts
    G03885559Courtesy of FORD MOTOR CO.
  19. Remove the RH lower transmission-to-engine bolt.
    20. Fig 14: Lower Right Transmission-To-Engine Bolt
    GF0011683Courtesy of FORD MOTOR CO.
    NOTE: RH shown, LH similar.
  20. Remove the 4 engine support insulator-to-crossmember nuts.
    21. Fig 15: Engine Support Insulator-To-Crossmember Nuts
    G03885561Courtesy of FORD MOTOR CO.
  21. Disconnect the power steering reservoir hose and the power steering pressure tube at the power steering pump.
    • Allow the fluid to drain into a drain pan.
    22. Fig 16: Power Steering Reservoir Hose And Pressure Tube Retainers
    G03885562Courtesy of FORD MOTOR CO.
  22. Remove the nut and position the transmission fluid cooler support bracket aside.
    23. Fig 17: Identifying Transmission Fluid Cooler Tube Support Bracket Nut
    G03885563Courtesy of FORD MOTOR CO.
  23. If equipped, remove the 3 bolts and position the A/C compressor aside.
    24. Fig 18: A/C Compressor Bolts
    G04612406Courtesy of FORD MOTOR CO.
  24. Remove the radiator grille support. For additional information, refer to FRONT END BODY PANELS article.
  25. Disconnect the upper radiator and the degas bottle coolant hoses from the radiator.
    26. Fig 19: Radiator Upper Hose & Overflow Hose
    GF0011684Courtesy of FORD MOTOR CO.
    NOTE: The large clutch assembly nut has a right-hand thread and must be rotated counterclockwise to remove it.
  26. Using the special tools, remove the fan blade assembly and fan clutch.
    27. Fig 20: Identifying Special Tools And Cooling Fan Assembly
    GF0002833Courtesy of FORD MOTOR CO.
  27. Disconnect the degas bottle coolant hose retainer from the fan shroud.
    28. Fig 21: Degas Bottle Coolant Hose Retainer
    G03885566Courtesy of FORD MOTOR CO.
  28. Remove the fan shroud, fan and fan clutch.
    1. Remove the bolts.
    2. Lift the fan shroud, fan and fan clutch from the vehicle.
    29. Fig 22: Fan Shroud & Bolts
    GF0011685Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  29. Remove the 4 bolts and the 2 radiator support brackets.
    30. Fig 23: Radiator Support Brackets Bolts
    G03886623Courtesy of FORD MOTOR CO.
  30. Remove the radiator from the vehicle.
    31. Fig 24: Positioning Radiator In Vehicle
    G03886624Courtesy of FORD MOTOR CO.
  31. Disconnect the A/C pressure cutoff switch electrical connector.
    32. Fig 25: A/C Pressure Cutoff Switch Electrical Connector
    G03886625Courtesy of FORD MOTOR CO.
    CAUTION: Use a wrench on each side of the fitting to prevent damage to the air conditioning (A/C) fitting.
  32. Disconnect the A/C compressor suction tube.
    33. Fig 26: A/C Compressor Suction Tube Fitting
    G03885571Courtesy of FORD MOTOR CO.
    CAUTION: Use a wrench on each side of the fitting to prevent damage to the air conditioning (A/C) fitting.
  33. Disconnect the condenser core refrigerant tubes.
    1. Disconnect the compressor discharge tube.
    2. Disconnect the condenser-to-evaporator tube.
    34. Fig 27: Condenser Core Refrigerant Tubes
    GF0011686Courtesy of FORD MOTOR CO.
    NOTE: RH shown, LH similar.
  34. Remove the A/C condenser core.
    1. Remove the bolts.
    2. Remove the A/C condenser brackets.
    3. Remove the A/C condenser core.
    35. Fig 28: A/C Condenser Core, Brackets & Bolts
    GF0011687Courtesy of FORD MOTOR CO.
  35. Set the hood latch aside.
    1. Remove the hood latch bolts.
    2. Disengage the cable routing clip.
    36. Fig 29: Hood Latch & Clip
    GF0011688Courtesy of FORD MOTOR CO.
  36. Remove the 2 bolts and set the power steering reservoir aside.
    37. Fig 30: Power Steering Reservoir Bolts
    G03886630Courtesy of FORD MOTOR CO.
    NOTE: Cover removed for clarity.
  37. Remove the 2 nuts and the battery feed cable at the power distribution box.
    38. Fig 31: Locating Battery Feed Cable Nuts At Power Distribution Box
    G03885576Courtesy of FORD MOTOR CO.
  38. Disconnect the battery feed wiring harness retainers and position aside.
    39. Fig 32: Routing Battery Feed Wiring Harness
    G03886632Courtesy of FORD MOTOR CO.
  39. If equipped, disconnect the air temperature sensor electrical connector.
    40. Fig 33: Air Temperature Sensor Electrical Connector
    G03885578Courtesy of FORD MOTOR CO.
  40. Disconnect the front impact severity sensor electrical connector.
    41. Fig 34: Front Impact Severity Sensor Electrical Connector
    G03885579Courtesy of FORD MOTOR CO.
  41. Disconnect the horn electrical connector.
    42. Fig 35: Horn Electrical Connector
    G03885580Courtesy of FORD MOTOR CO.
    NOTE: RH shown, LH similar.
  42. Remove the 8 bolts and the upper radiator support.
    43. Fig 36: Identifying Upper Radiator Support Bolts
    G03886636Courtesy of FORD MOTOR CO.
    NOTE: RH shown, LH similar.
  43. Remove the pin-type retainers and the RH and LH air deflectors.
    44. Fig 37: Locating Pin-Type Retainers
    G03886637Courtesy of FORD MOTOR CO.
  44. Set aside the LH side of the headlamp dash panel junction wiring harness.
    1. Remove the screw.
    2. Disengage the routing clips.
    45. Fig 38: Left Side Of Headlamp Dash Panel Junction Wiring Harness
    GF0011689Courtesy of FORD MOTOR CO.
  45. Set aside the RH side of the headlamp dash panel junction wiring harness.
    1. Disconnect the electrical connector.
    2. Remove the screw.
    3. Disengage the routing clips.
    46. Fig 39: Right Side Of Headlamp Dash Panel Junction Wiring Harness
    GF0011690Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  46. Remove the 12 bolts and the lower radiator support.
    47. Fig 40: Identifying Lower Radiator Support Bolts
    G03886640Courtesy of FORD MOTOR CO.
  47. Disconnect the lower radiator coolant hose from the oil filter adapter water inlet and set aside.
    48. Fig 41: Identifying Lower Radiator Hose
    G03886149Courtesy of FORD MOTOR CO.
  48. Rotate the tensioner clockwise to release belt tension and remove the accessory drive belt.
    49. Fig 42: Rotating Tensioner Clockwise
    GF0000336Courtesy of FORD MOTOR CO.
  49. Disconnect the generator electrical connections.
    1. Remove the B+ terminal nut and disconnect the terminal.
    2. Disconnect the S electrical connector.
    3. Disconnect the ASI electrical connector.
    50. Fig 43: Generator Electrical Connections
    GF0011691Courtesy of FORD MOTOR CO.
  50. Remove the 2 bolts and the generator.
    51. Fig 44: Locating Generator Bolts
    G03885512Courtesy of FORD MOTOR CO.
  51. Disconnect the engine wiring harness from the PCM bracket.
    52. Fig 45: Identifying Engine Wiring Harness To PCM Bracket Retainer
    G03885211Courtesy of FORD MOTOR CO.
  52. Disconnect the PCM electrical connectors. Position the engine wiring harness onto the engine.
    53. Fig 46: Powertrain Control Module (PCM) Electrical Connectors
    G03885591Courtesy of FORD MOTOR CO.
  53. Disconnect the engine wiring harness electrical connectors.
    54. Fig 47: Identifying Engine Wiring Harness Electrical Connectors
    G03885233Courtesy of FORD MOTOR CO.
    NOTE: Windsor engine shown, Romeo engine similar.
  54. Disconnect the electrical connectors, remove the nut, ground strap and mounting bracket.
    55. Fig 48: Electrical Connectors And Ground Strap Bracket Retaining Nut
    G03885234Courtesy of FORD MOTOR CO.
  55. Remove the engine oil filler tube support strap bolt.
    56. Fig 49: Engine Oil Filler Tube Support Strap Bolt
    G03885594Courtesy of FORD MOTOR CO.
  56. Remove the fluid level indicator and disconnect the attachments at the transmission fluid filler tube.
    1. Remove the fluid level indicator.
    2. Disconnect the rear heater hose hanger.
    57. Fig 50: Transmission Fluid Level Indicator & Rear Heater Hose Hanger
    GF0011692Courtesy of FORD MOTOR CO.
  57. Disconnect the evaporative emission (EVAP) canister purge valve electrical connector.
    58. Fig 51: Locating Evaporative Emission (EVAP) Canister Purge Valve Electrical Connector
    G03885596Courtesy of FORD MOTOR CO.

    5.4L (2V) engine 

  58. Remove the nut and the transmission fluid filler tube, and allow the fluid to drain into a suitable container.
    59. Fig 52: Identifying Transmission Fluid Indicator Tube Retaining Nut
    G03885597Courtesy of FORD MOTOR CO.
  59. Release the wiring retainers from the heater outlet tube bracket.
    1. Release the knock sensor (KS) electrical connector retainer.
    2. Release the engine harness routing clip retainer.
    60. Fig 53: Locating Engine Harness Routing Clip Retainers
    G04612441Courtesy of FORD MOTOR CO.
  60. Disconnect the coolant hose from the heater outlet tube.
    61. Fig 54: View Of Heater Outlet Tube Hose
    G03885599Courtesy of FORD MOTOR CO.
  61. Remove the 2 heater outlet tube studs.
    62. Fig 55: Identifying Heater Outlet Tube Studs
    G03885600Courtesy of FORD MOTOR CO.

    All engines 

  62. Remove the heater outlet tube.
    • Discard the O-ring seals.
    63. Fig 56: Heater Outlet Tube
    GF0011662Courtesy of FORD MOTOR CO.
  63. Release the transmission wiring harness connector retainer from the bracket. Disconnect the transmission wiring harness and the LH and RH heated oxygen sensor (HO2S) electrical connectors.
    64. Fig 57: View Of Transmission And Heated Oxygen Sensor (HO2S) Electrical Connectors
    G04612445Courtesy of FORD MOTOR CO.
  64. Remove the 4 upper transmission-to-engine bolts and the fuel line, and the LH HO2S brackets.
    65. Fig 58: Upper Transmission-To-Engine Bolts
    G03886655Courtesy of FORD MOTOR CO.
  65. Install the special tool as shown.
    66. Fig 59: Identifying Special Tool (303-F047)
    G03962845Courtesy of FORD MOTOR CO.
  66. Support the transmission with a jack.
  67. Using a suitable floor crane, remove the engine assembly from the vehicle.
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