Automatic Transmission: Removal: Transaxle: Removal

All vehicles 

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING .
2. Disconnect the mass air flow (MAF) sensor electrical connector and the wiring harness fastener from the air cleaner assembly.
Fig 1: Locating Mass Air Flow (MAF) Sensor Electrical Connector & Wiring Harness Fastener
Courtesy of FORD MOTOR CO.
3. Disconnect the brake booster vacuum hose from the air cleaner outlet pipe.
Fig 2: Locating Brake Booster Vacuum Hose
Courtesy of FORD MOTOR CO.
4. Disconnect the engine breather from the air cleaner assembly.
Fig 3: Locating Engine Breather
Courtesy of FORD MOTOR CO.
5. Remove the air cleaner assembly bracket bolt.
Fig 4: Locating Air Cleaner Assembly Bracket Bolt
Courtesy of FORD MOTOR CO.
6. Loosen the air cleaner outlet pipe clamp at the throttle body (TB) and remove the air cleaner and air cleaner outlet pipe assembly.
Fig 5: Locating Air Cleaner Outlet Pipe Clamp
Courtesy of FORD MOTOR CO.
7. Remove the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
8. Remove the battery tray.
   1. Disconnect the wiring harness fasteners.
   2. Remove the 3 bolts and the battery tray.
Fig 6: Identifying Wiring Harness Fasteners, Battery Tray & Bolts
Courtesy of FORD MOTOR CO.
9. Remove the upper intake manifold. For additional information, refer to ENGINE - 3.5L .
10. Disconnect the selector lever cable end from the manual control lever.
Fig 7: Locating Selector Lever Cable End From Manual Lever
Courtesy of FORD MOTOR CO.
11. Remove the 3 selector lever cable bracket bolts and position aside the selector lever cable.
Fig 8: Identifying Selector Lever Cable Bracket Bolts
Courtesy of FORD MOTOR CO.
12. Remove the starter motor electrical terminal cover.
Fig 9: Locating Starter Motor Electrical Terminal Cover
Courtesy of FORD MOTOR CO.
13. Position the starter cable boot back and remove the starter terminals from the starter.
Fig 10: Identifying Wire Terminals From Starter
Courtesy of FORD MOTOR CO.
14. Disconnect the wiring harness fastener from the starter motor stud bolt.
Fig 11: Identifying Wiring Harness Retainer From Starter Motor Stud Bolt
Courtesy of FORD MOTOR CO.
15. Remove the 2 bolts and the starter.
Fig 12: Identifying Bolt, Stud Bolt & Starter
Courtesy of FORD MOTOR CO.
16. Disconnect the fuel hose routing clip from the transaxle stud and position the fuel hose aside.
Fig 13: Identifying Fuel Hose Routing Clip From Transaxle Stud
Courtesy of FORD MOTOR CO.
17. Disconnect the transaxle electrical connector.
Fig 14: Identifying Transaxle Control Electrical Connector
Courtesy of FORD MOTOR CO.
18. Remove the top 4 torque converter housing bolts.
Fig 15: Locating Torque Converter Housing Bolts
Courtesy of FORD MOTOR CO.
NOTE: The coolant hoses do not need to be removed from the engine.
19. Remove the coolant hoses from the transmission fluid filler tube and position aside.
Fig 16: Identifying Coolant Hoses From Transmission Fluid Filler Tube
Courtesy of FORD MOTOR CO.
NOTE: The coolant hoses have been removed for clarity.
20. Remove the transmission fluid level indicator.
Fig 17: Identifying Transmission Fluid Level Indicator
Courtesy of FORD MOTOR CO.
NOTE: The coolant hoses have been removed for clarity.
21. Remove the nut, rotate the transmission fluid filler tube counterclockwise 90 degrees and remove the transmission fluid filler tube.
Fig 18: Identifying Transmission Fluid Filler Tube
Courtesy of FORD MOTOR CO.
22. Install the special tool on the LH cylinder head.
Fig 19: Installing Special Tool (303-1245) On LH Cylinder Head
Courtesy of FORD MOTOR CO.
23. Install the special tools and support the engine.
Fig 20: Installing Special Tools & Supporting Engine
Courtesy of FORD MOTOR CO.
24. Remove the transaxle support insulator through bolt.
Fig 21: Identifying Transaxle Support Insulator Bolt
Courtesy of FORD MOTOR CO.
25. Remove the 3 nuts, the bolt and the transaxle support insulator bracket.
Fig 22: Identifying Transaxle Support Insulator Bracket, Nuts & Bolts
Courtesy of FORD MOTOR CO.
26. Remove the RH splash shield.
    1. Remove the screws.
    2. Remove the push pin fasteners and the RH splash shield.
Fig 23: Locating Push Pin Fasteners & RH Splash Shield
Courtesy of FORD MOTOR CO.
27. Remove the 3 push pin fasteners, the 7 screws and the front splash shield.
Fig 24: Locating Push Pin Fasteners & Front Splash Shield Screws
Courtesy of FORD MOTOR CO.
28. Remove the transmission fluid drain plug and allow the transmission fluid to drain.
Fig 25: 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 26: Locating Transmission Fluid Drain Plug
Courtesy of FORD MOTOR CO.
30. Remove the 3 RH subframe-to-lower bumper nuts.
Fig 27: Locating RH Subframe-To-Lower Bumper Nuts
Courtesy of FORD MOTOR CO.
31. Remove the 3 LH subframe-to-lower bumper nuts and separate the front support from the subframe.
Fig 28: Locating LH Subframe-To-Lower Bumper Nuts
Courtesy of FORD MOTOR CO.
32. Remove the 3 power steering tube bracket bolts from the RH side of the subframe and position the power steering tube aside.
Fig 29: Identifying Power Steering Tube Bracket Bolts
Courtesy of FORD MOTOR CO.
NOTE: RH side shown, LH side similar.
33. Remove the 2 sway bar link-to-control arm nuts and separate the sway bar links from the lower control arms.
Fig 30: Locating Stabilizer Bar Link Nut
Courtesy of FORD MOTOR CO.
NOTE: RH side shown, LH side similar.
34. Remove the 2 front halfshaft nuts.
Fig 31: Locating RH Front Halfshaft Nut
Courtesy of FORD MOTOR CO.
NOTE: RH side shown, LH side similar.
35. Remove the lower control arm-to-knuckle pinch bolts and separate the lower control arms from the knuckles.
Fig 32: Locating Ball Joint Pinch Bolt
Courtesy of FORD MOTOR CO.
NOTE: RH side shown, LH side similar.
36. Using the special tool, separate the halfshafts from the wheel hubs.
Fig 33: Separating Halfshaft From Wheel Hub Using Special Tool (205-D070)
Courtesy of FORD MOTOR CO.

All wheel drive (AWD) vehicles 

37. Remove the 2 RH halfshaft bearing support bracket bolts and the RH halfshaft.
Fig 34: Locating RH Halfshaft Bearing Support Bracket Bolts
Courtesy of FORD MOTOR CO.
38. Inspect the halfshaft hub for wear or damage and replace the 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 35: Identifying Differential Side Gear Splines, Halfshaft Bushing & Differential Seal
Courtesy of FORD MOTOR CO.
NOTE: A new halfshaft seal must be installed anytime the RH halfshaft is removed.
NOTE: The seal deflector will be damaged during removal. Be careful not to damage the cover seal directly behind the seal deflector.
39. Remove the seal deflector.
Fig 36: Identifying Seal Deflector
Courtesy of FORD MOTOR CO.
40. Using the special tools, remove the halfshaft seal from the power transfer unit (PTU).
Fig 37: Removing Intermediate Shaft Seal Using Special Tools (100-001) & (308-047)
Courtesy of FORD MOTOR CO.

Front wheel drive (FWD) vehicles 

41. Remove the bolts and the power steering rack heat shield.
Fig 38: Locating Power Steering Rack Heat Shield Bolts
Courtesy of FORD MOTOR CO.
42. Remove the 2 catalytic converter support bracket bolts.
Fig 39: Locating Catalytic Converter Support Bracket Bolts
Courtesy of FORD MOTOR CO.
43. Remove the bolt, the nut and the catalytic converter support bracket.
Fig 40: Identifying RH Catalytic Converter Support Bracket & Bolts
Courtesy of FORD MOTOR CO.
44. Remove the 2 bolts and the RH halfshaft.
Fig 41: Locating Stud Bolts & RH Halfshaft/Intermediate Shaft Assembly
Courtesy of FORD MOTOR CO.
45. Inspect the halfshaft hub for wear or damage and replace the 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 42: Identifying Differential Side Gear Splines, Halfshaft Bushing & Differential Seal
Courtesy of FORD MOTOR CO.

All vehicles 

46. Using the special tools, remove the LH halfshaft.
Fig 43: Removing Halfshaft Using Special Tools (100-001), (205-241) & (205-290)
Courtesy of FORD MOTOR CO.
47. Inspect the halfshaft hub for wear or damage and replace the 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 44: Identifying Differential Side Gear Splines, Halfshaft Bushing & Differential Seal
Courtesy of FORD MOTOR CO.
48. Loosen the Y-pipe clamp and disconnect the 2 exhaust hangers.
Fig 45: Locating Exhaust Flexible Pipe Clamp & Exhaust Hangers
Courtesy of FORD MOTOR CO.
49. Remove the 4 nuts and the Y-pipe assembly.
Fig 46: Locating Exhaust Flexible Pipe, Y-Pipe & Nuts
Courtesy of FORD MOTOR CO.
50. Remove the 4 bolts and position the steering rack aside, using a suitable length of mechanic's wire.
Fig 47: Locating Steering Rack Bolts
Courtesy of FORD MOTOR CO.
51. Remove the 4 bolts and position the sway bar aside, using a suitable length of mechanic's wire.
Fig 48: Locating Stabilizer Bar & Bolts
Courtesy of FORD MOTOR CO.
52. Remove the 2 nuts and the roll restrictor heat shield.
Fig 49: Locating Roll Restrictor Heat Shield Nuts
Courtesy of FORD MOTOR CO.
53. Remove the 3 bolts from the roll restrictor bracket.
Fig 50: Locating Roll Restrictor-To-Transaxle Bracket Plate Bolts
Courtesy of FORD MOTOR CO.
54. Support the subframe using a suitable drivetrain lift.
55. Remove the 2 nuts, 4 bolts and the subframe support brackets.
Fig 51: Locating Subframe Support Brackets, Nuts & Bolts
Courtesy of FORD MOTOR CO.
56. Remove the 2 front subframe nuts.
Fig 52: Locating Front Subframe Nuts
Courtesy of FORD MOTOR CO.
57. Remove the 2 middle subframe nuts and remove the subframe.
Fig 53: Locating Middle Subframe Nuts
Courtesy of FORD MOTOR CO.
58. Remove the 3 bolts and the roll restrictor bracket.
Fig 54: Locating Transaxle Bracket Bolts
Courtesy of FORD MOTOR CO.

AWD vehicles 

59. Index-mark the driveshaft, remove the 4 bolts and position the driveshaft aside.
Fig 55: Locating Driveshaft Aside Bolts
Courtesy of FORD MOTOR CO.
60. Disconnect the RH catalyst monitor electrical connector.
Fig 56: Identifying RH Catalyst Monitor Electrical Connector
Courtesy of FORD MOTOR CO.
61. Remove the 2 catalytic converter support bracket bolts.
Fig 57: Locating Catalytic Converter Support Bracket Bolts
Courtesy of FORD MOTOR CO.
62. Remove the 4 RH catalytic converter nuts and the RH catalytic converter.
Fig 58: Locating RH Catalytic Converter Nuts
Courtesy of FORD MOTOR CO.
63. Remove the 5 bolts and the PTU support bracket.
Fig 59: Locating Power Transfer Unit (PTU) Support Bracket & Bolts
Courtesy of FORD MOTOR CO.
64. Remove the 5 bolts and the PTU.
Fig 60: Identifying PTU & Bolts
Courtesy of FORD MOTOR CO.

All vehicles 

65. Remove the 2 fasteners and the inspection cover.
Fig 61: Locating Oil Fasteners On Inspection Cover
Courtesy of FORD MOTOR CO.
66. Remove and discard the 3 torque converter bolts.
Fig 62: Locating Torque Converter Bolts
Courtesy of FORD MOTOR CO.
67. Remove the 2 secondary latches from the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.
Fig 63: Locating Secondary Latches From Transmission Fluid Cooler Tubes
Courtesy of FORD MOTOR CO.
68. Using the special tool, disconnect the transmission fluid cooler tubes from the transmission fluid cooler thermal bypass valve.
Fig 64: Disconnecting Transmission Cooling Tubes Using Special Tool (307-569)
Courtesy of FORD MOTOR CO.
69. Using the special tool and a suitable transmission jack, support the transaxle.
Fig 65: Supporting Transaxle Using Special Tool (209-00152) & A Suitable Transmission Jack
Courtesy of FORD MOTOR CO.
70. Remove the 7 torque converter housing bolts and remove the transaxle from the vehicle.
Fig 66: Locating torque converter housing bolts
Courtesy of FORD MOTOR CO.
71. Inspect the torque converter housing mating surface to make sure that the dowel pins did not come out of the engine block when the transaxle was removed. If the dowel pin is stuck in the torque converter housing, remove the dowel pin from the torque converter housing.
Fig 67: Locating dowel pin from torque converter housing
Courtesy of FORD MOTOR CO.
72. Remove and discard the 2 transmission fluid cooler tube bolts.
Fig 68: Locating transmission fluid cooler tube bolt
Courtesy of FORD MOTOR CO.
73. Remove the 2 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 69: Removing Nuts & Pulling Transmission Fluid Cooler Thermal Bypass Valve & Transmission Fluid Cooler Tubes Straight Up
Courtesy of FORD MOTOR CO.
74. Inspect the transaxle case to make 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 70: Locating Transmission Fluid Cooler Tube Seals & Backing Rings
Courtesy of FORD MOTOR CO.
75. If the transaxle is to be overhauled or if installing a new transaxle, carry out transmission fluid cooler backflushing and cleaning. For additional information, refer to Transmission Fluid Cooler Backflushing and Cleaning .
76. If a replacement transaxle assembly is being installed or a new solenoid body is installed, the PCM will have to be reflashed with a new solenoid body strategy and ID data file. For additional information, refer to Solenoid Body Strategy .