ECVT (Hybrid): Removal: Transaxle

SPECIAL TOOLS CHART

	2, 200# Floor Crane, Fold Away 300-OTC1819E or equivalent
	Powertrain Lift 014-00765 or equivalent
	Remover, Tie-Rod End 211-105 (T85M-3395-A)
	Spreader Bar 303-D089 (D93P-6001-A3) (part of 303-DS086) or equivalent
	Adjustable Grip Arm, 1735A 014-00001 or equivalent

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

All vehicles

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING article.
Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
Remove the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES article.

NOTE: Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent).

Fig 1: Holding Steering Wheel In Straight-Ahead Position

Courtesy of FORD MOTOR CO.

Using a suitable holding device, hold the steering wheel in the straight-ahead position and put the ignition key in the OFF position.
Disable the vehicle high voltage electrical system. For additional information, refer to HIGH VOLTAGE TRACTION BATTERY article.
Recover the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS article.
Drain the cooling system. For additional information, refer to ENGINE COOLING - HYBRID article.
Drain the Motor Electronics Cooling System (MECS). For additional information, refer to TRANSAXLE/TRANSMISSION COOLING - HYBRID article.
Remove the engine coolant degas bottle. For additional information, refer to ENGINE COOLING - HYBRID article.
Remove the engine Air Cleaner (ACL). For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING - HYBRID article.
Remove the accessory drive belt. For additional information, refer to ACCESSORY DRIVE - HYBRID article.
Disconnect the fuel supply tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.

Fig 2: Locating Fuel Supply Tube
Courtesy of FORD MOTOR CO.
Remove the front wheels and tires. For additional information, refer to WHEELS AND TIRES article.
Remove the bolts and the lateral support crossmember.

Fig 3: Locating Lateral Support Crossmember And Bolts
Courtesy of FORD MOTOR CO.
Remove the catalytic converter inlet pipe-to-converter nuts.

Fig 4: Locating Catalytic Converter Inlet Pipe-To-Converter Nuts
Courtesy of FORD MOTOR CO.
Remove the catalytic converter inlet pipe-to-catalytic manifold converter nuts and remove the pipe.

Fig 5: Identifying Catalytic Converter Inlet Pipe-To-Catalytic Manifold Converter Nuts
Courtesy of FORD MOTOR CO.
Remove the brake hose retainer and the ABS sensor retaining bolt from the LH strut.

Fig 6: Locating Brake Hose Retainer And ABS Sensor Retaining Bolt
Courtesy of FORD MOTOR CO.
Disconnect the LH suspension.
1. Remove the nut and disconnect the stabilizer bar link.
2. Remove and discard the tie-rod end retaining nut.
  
  Fig 7: Identifying Stabilizer Bar Link And Retaining Nut
  Courtesy of FORD MOTOR CO.
Remove the brake hose retainer and the ABS sensor retaining bolt from the RH strut.

Fig 8: Locating Brake Hose Retainer And ABS Sensor Retaining Bolt
Courtesy of FORD MOTOR CO.
Disconnect the RH suspension.
1. Remove the nut and disconnect the stabilizer bar link.
2. Remove and discard the tie-rod end retaining nut.
  
  Fig 9: Disconnecting Stabilizer Bar Link
  Courtesy of FORD MOTOR CO.

NOTE: LH shown in illustration, RH similar.

Fig 10: Disconnecting LH And RH Tie Rod End From Steering Knuckle

Courtesy of FORD MOTOR CO.

Using the Tie-Rod End Remover, disconnect the LH and RH tie-rod end from the steering knuckle.
Drain the transmission fluid. For additional information, refer to TRANSMISSION FLUID DRAIN AND REFILL .
Remove the front LH halfshaft and intermediate shaft. For additional information, refer to FRONT DRIVE HALFSHAFTS article.
All-Wheel Drive (AWD) vehicles
Remove the driveshaft. For additional information, refer to DRIVESHAFT article.
Remove the catalytic converter bracket bolts.

Fig 11: Locating Catalytic Converter Bracket Bolts
Courtesy of FORD MOTOR CO.

NOTE: Catalytic converter manifold removed for clarity.

Fig 12: Locating Bolts And Transfer Case-To-Engine Bracket

Courtesy of FORD MOTOR CO.

Remove the bolts and the Power Transfer Unit (PTU)-to-engine bracket.
Remove the PTU heat shield bolts and the PTU heat shield.

Fig 13: Locating PTU Heat Shield Bolts
Courtesy of FORD MOTOR CO.
Disconnect the PTU vent hose and position it.

Fig 14: Locating PTU Vent Hose
Courtesy of FORD MOTOR CO.

NOTE: Catalytic converter manifold removed for clarity.

Fig 15: Identifying Transfer Case-To-Transaxle Bolts And Transfer Case

Courtesy of FORD MOTOR CO.

Remove the PTU-to-transaxle bolts and remove the PTU.
All vehicles
Disconnect the heater hoses from the heater core.

Fig 16: Locating Heater Hose Clamps
Courtesy of FORD MOTOR CO.
Disconnect the upper radiator hose from the radiator.

Fig 17: Locating Upper Radiator Hose
Courtesy of FORD MOTOR CO.
Disconnect the brake booster vacuum tube from the brake booster.

Fig 18: Locating Brake Booster Vacuum Tube
Courtesy of FORD MOTOR CO.
Disconnect the PCM center electrical connector.
- Remove the wiring harness retainer nut.
  
  Fig 19: Locating PCM Center Electrical Connector
  Courtesy of FORD MOTOR CO.
If equipped, disconnect the block heater electrical connector.
- Detach the harness retainer clips and position harness.
  
  Fig 20: Locating Block Heater Electrical Connector
  Courtesy of FORD MOTOR CO.
Disconnect the engine control harness electrical connector.

Fig 21: Locating Engine Control Harness Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the upper Evaporative Emission (EVAP) tube quick connect coupling from the purge valve. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.

Fig 22: Locating Upper Evaporative Emission Tube Quick Connect Coupling
Courtesy of FORD MOTOR CO.
Remove the selector lever cable fastener from the engine front cover stud bolt.

Fig 23: Locating Selector Lever Cable Fastener From Engine Front Cover Stud Bolt
Courtesy of FORD MOTOR CO.
Remove the selector lever cable fastener from the A/C compressor mounting bracket.

Fig 24: Locating Selector Lever Cable Fastener From A/C Compressor Mounting Bracket
Courtesy of FORD MOTOR CO.
Remove the stud bolt and disconnect the transaxle harness electrical connector.

Fig 25: Locating Stud Bolt And Transaxle Harness Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the low voltage electrical connectors and the engine harness-to-body harness retainer.

Fig 26: Locating Low Voltage Electrical Connectors And Engine Harness-To-Body Harness Retainer
Courtesy of FORD MOTOR CO.
Disconnect the coolant vent hose.

Fig 27: Locating Coolant Vent Hose
Courtesy of FORD MOTOR CO.
Release the locking tab and disconnect the DC-to-DC converter electrical connector and 2 wire harness retainers.

Fig 28: Locating DC-TO-DC Converter Electrical Connector And Wire Harness Retainers
Courtesy of FORD MOTOR CO.
Remove the nuts and position the DC-to-DC converter.

Fig 29: Identifying DC-To-DC Converter
Courtesy of FORD MOTOR CO.
Disconnect the transaxle coolant temperature sensor electrical connector and pin-type retainer.

Fig 30: Locating Transaxle Coolant Temperature Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the transaxle coolant hoses.

Fig 31: Identifying Transaxle Coolant Hoses
Courtesy of FORD MOTOR CO.
Remove the bolts and the transaxle control snow shield.

Fig 32: Locating Bolts And Transaxle Control Snow Shield
Courtesy of FORD MOTOR CO.
Disconnect the selector lever cable.
- Release the selector lever cable from the manual control lever.
- Remove the nuts from the selector lever cable bracket.
  
  Fig 33: Locating Selector Lever Cable Bracket And Nuts
  Courtesy of FORD MOTOR CO.
Remove the harness fasteners, the nut and the ground cable.

Fig 34: Locating Harness Fasteners, Nut And Ground Cable
Courtesy of FORD MOTOR CO.
Disconnect the vacuum pump assembly electrical connector and detach the harness retainer.

Fig 35: Locating Vacuum Pump Assembly Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the 2 bolts and position the MECS pump.

Fig 36: Locating Bolts And MECS Pump
Courtesy of FORD MOTOR CO.
Remove the nut and disconnect the A/C tube from the A/C compressor.
- Discard the gasket.
  
  Fig 37: Locating Nut And A/C Tube From A/C Compressor
  Courtesy of FORD MOTOR CO.
Remove the nut and disconnect the A/C tube from the A/C compressor.
- Discard the gasket.
  
  Fig 38: Locating Nut And A/C Tube From A/C Compressor
  Courtesy of FORD MOTOR CO.
Remove the 2 bolts and disconnect the auxiliary coolant pump electrical connector.
- Position the auxiliary coolant pump.
  
  Fig 39: Locating Bolts And Auxiliary Coolant Pump Electrical Connector
  Courtesy of FORD MOTOR CO.
Disconnect the lower radiator hose from the radiator.
- Release the wire clip and disconnect the hose.
  
  Fig 40: Locating Lower Radiator Hose From Radiator
  Courtesy of FORD MOTOR CO.
Remove the lower insulator through bolt.

Fig 41: Locating Lower Insulator Through Bolt
Courtesy of FORD MOTOR CO.
Remove the rear roll restrictor-to-crossmember through bolt.

Fig 42: Locating Rear Roll Restrictor-To-Crossmember Bolt
Courtesy of FORD MOTOR CO.
Remove the nut, bolts and the engine support crossmember.
- Discard the nut.
  
  Fig 43: Identifying Engine Support Crossmember Nut And Bolts
  Courtesy of FORD MOTOR CO.

NOTE: The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.

Fig 44: Locating Transaxle-To-Engine Bolts

Courtesy of FORD MOTOR CO.

Remove the transaxle-to-engine bolts.

NOTE: The transaxle-to-engine bolts differ in length, mark the bolts for correct installation.

Fig 45: Locating Transaxle-To-Engine Bolts

Courtesy of FORD MOTOR CO.

Remove the transaxle-to-engine bolts.
Remove the rear insulator through bolt.

Fig 46: Locating Rear Insulator Through Bolt
Courtesy of FORD MOTOR CO.

NOTE: Do not allow the steering wheel to rotate while the intermediate shaft is disconnected or damage to the clockspring can result. If there is evidence that the shaft has rotated, the clockspring must be removed and re-centered. For additional information, refer to SUPPLEMENTAL RESTRAINT SYSTEM article.

Fig 47: Locating Steering Column Coupling Pinch Bolt

Courtesy of FORD MOTOR CO.

Remove and discard the steering column coupling pinch bolt and separate the coupling from the steering gear.
Remove the rear roll restrictor bolts, the rear roll restrictor bracket and the rear roll restrictor.

Fig 48: Locating Bolts, Roll Restrictor And Bracket
Courtesy of FORD MOTOR CO.
Using the Powertrain Lift, support the subframe.

NOTE: Do not allow the front subframe rear bolts to come out of the lower control arm bushing.

NOTE: RH shown in illustration, LH similar.

Fig 49: Locating Subframe Bolts

Courtesy of FORD MOTOR CO.

Loosen the 2 subframe bolts.

NOTE: RH shown in illustration, LH similar.

Remove the 2 subframe nuts and lower the subframe.
- Remove the subframe from the Powertrain Lift.
  
  Fig 50: Locating Subframe Nuts
  Courtesy of FORD MOTOR CO.

NOTE: Due to the weight of the transaxle, special care should be taken to mount the powertrain securely to the Powertrain Lift.

Fig 51: Lifting Engine To Powertrain

Courtesy of FORD MOTOR CO.

Using the Powertrain Lift and Adjustable Grip Arm, secure the engine to the Powertrain Lift.
Remove the engine mount bracket bolt.

Fig 52: Locating Engine Mount Bracket Bolt
Courtesy of FORD MOTOR CO.
Remove the 3 nuts and the engine mount bracket.

Fig 53: Locating Nuts And Engine Mount Bracket
Courtesy of FORD MOTOR CO.
Remove the upper insulator bracket bolt, nut and remove the bracket.

Fig 54: Locating Upper Insulator Bracket Bolt And Nut
Courtesy of FORD MOTOR CO.
Remove the upper insulator through bolt.

Fig 55: Locating Upper Insulator Through Bolt
Courtesy of FORD MOTOR CO.
Remove the upper insulator nuts.

Fig 56: Locating Upper Insulator Nuts
Courtesy of FORD MOTOR CO.
Remove the upper insulator.

Fig 57: Locating Upper Insulator
Courtesy of FORD MOTOR CO.
Lower the engine and transaxle from the vehicle.
Using the Floor Crane and Spreader Bar, remove the engine and transaxle from the Powertrain Lift.
Release the locking tab and disconnect the high voltage wiring harness electrical connector.

Fig 58: Locating High Voltage Wiring Harness Electrical Connector
Courtesy of FORD MOTOR CO.

NOTE: The transaxle-to-engine bolts differ in length, mark the bolts for correct installation.

Remove the remaining engine-to-transaxle bolts and separate the engine and transaxle.

NOTE: Due to packaging requirements, the correct bolt must be used at the damper locations.

NOTE: The damper contains a clutch which is designed to slip briefly during vehicle operation. It is essential that no grease, oil or cleaning solvents be allowed to contaminate the slip clutch. Do not use grease on transmission input shaft. Should the damper become contaminated, it must be replaced.

NOTE: If replacing the transaxle, remove the lower insulator bracket for installation on the new transaxle.

Fig 59: Locating Transaxle Damper Bolts

Courtesy of FORD MOTOR CO.

Remove the bolts and the transaxle damper.
- Tighten bolts to 90 Nm (66 lb-ft).