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 article.
2. Disconnect the Mass Air Flow (MAF) sensor electrical connector.
Fig 1: Identifying MAF Sensor Connector
Courtesy of FORD MOTOR CO.
3. Disconnect the engine breather from the Air Cleaner (ACL) assembly.
Fig 2: Locating Engine Breather
Courtesy of FORD MOTOR CO.
4. Remove the ACL assembly bracket bolts.
Fig 3: Identifying Bolts
Courtesy of FORD MOTOR CO.
5. Disconnect the brake booster vacuum hose from the ACL outlet pipe.
Fig 4: Identifying ACL Outlet Pipe
Courtesy of FORD MOTOR CO.
6. Loosen the ACL outlet pipe clamp at the Throttle Body (TB) and remove the ACL and ACL outlet pipe assembly.
Fig 5: Identifying ACL Outlet Pipe Clamp
Courtesy of FORD MOTOR CO.
7. Remove the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
8. Detach the wiring harness retainers from the battery tray.
Fig 6: Identifying Retainers
Courtesy of FORD MOTOR CO.
9. Remove the lower battery tray bracket bolts.
Fig 7: Identifying Bolts
Courtesy of FORD MOTOR CO.
10. Remove the upper battery tray bolt and nut and remove the battery tray and bracket.
Fig 8: Identifying Bolt, Nut And Bracket
Courtesy of FORD MOTOR CO.
11. Remove the upper intake manifold. For additional information, refer to ENGINE - 3.5L article.
12. Disconnect the selector lever cable end from the manual control lever.
Fig 9: Locating Selector Lever Cable End From Manual Lever
Courtesy of FORD MOTOR CO.
13. Remove the selector lever cable bracket bolts and position aside the selector lever cable and bracket.
Fig 10: Identifying Bolts
Courtesy of FORD MOTOR CO.
14. Remove the starter motor positive terminal cover.
Fig 11: Identifying Starter Motor Solenoid Cover
Courtesy of FORD MOTOR CO.
15. Remove the starter terminals from the starter.
Fig 12: Identifying Wire Terminals From Starter
Courtesy of FORD MOTOR CO.
16. Disconnect the wiring harness fastener from the starter motor studbolt.
Fig 13: Identifying Wiring Harness Retainer From Starter Motor Stud Bolt
Courtesy of FORD MOTOR CO.
17. Remove the bolt, studbolt and the starter.
Fig 14: Identifying Bolt, Stud Bolt & Starter
Courtesy of FORD MOTOR CO.
18. If equipped, remove the 2 auxiliary coolant pump bracket nuts and position the auxiliary coolant pump aside.
Fig 15: Identifying Auxiliary Coolant Pump
Courtesy of FORD MOTOR CO.
19. Disconnect the transaxle electrical connector and remove the wiring harness fastener from the main control cover stud.
Fig 16: Identifying Connector And Wiring Harness Fastener
Courtesy of FORD MOTOR CO.
20. Position the coolant hoses aside from the transmission fluid filler tube.
Fig 17: Identifying Coolant Hoses From Transmission Fluid Filler Tube
Courtesy of FORD MOTOR CO.
NOTE: Coolant hoses removed for clarity.
21. Remove the transmission fluid level indicator.
Fig 18: Identifying Transmission Fluid Level Indicator
Courtesy of FORD MOTOR CO.
NOTE: Coolant hoses removed for clarity.
22. Remove the nut, rotate the transmission fluid filler tube counterclockwise 90 degrees and remove the transmission fluid filler tube.
Fig 19: Identifying Transmission Fluid Filler Tube
Courtesy of FORD MOTOR CO.
23. Remove the top torque converter housing bolts.
Fig 20: Identifying Bolts
Courtesy of FORD MOTOR CO.
24. Install the Engine Lift Eye onto the LH cylinder head.
Fig 21: Special Tool (303-1245) On LH Cylinder Head
Courtesy of FORD MOTOR CO.
25. Install the Engine Support Bar and Engine Spreader Bar to support the engine.
Fig 22: Engine Support Bar & Engine Spreader Bar
Courtesy of FORD MOTOR CO.
26. Remove the front wheels. For additional information, refer to WHEELS AND TIRES article.
27. Remove the pushpin fasteners and the RH splash shield.
Fig 23: Identifying Pushpin Fasteners
Courtesy of FORD MOTOR CO.
28. Remove the screws, pushpin fasteners and the front splash shield.
Fig 24: Identifying Pushpin Fasteners
Courtesy of FORD MOTOR CO.
29. 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.
30. 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.
31. Remove the 3 power steering tube bracket bolts from the LH side of the subframe and position the power steering tube aside.
Fig 27: Power Steering Tube Bracket Bolt
Courtesy of FORD MOTOR CO.
NOTE: RH side shown in illustration, LH side similar.
32. Remove and discard the RH and LH front halfshaft nuts.
Fig 28: Locating RH Front Halfshaft Nut
Courtesy of FORD MOTOR CO.
NOTE: RH side shown in illustration, LH side similar.
33. Remove and discard the lower control arm ball joint nuts and separate the lower control arms from the knuckles.
Fig 29: Identifying Nut And Wheel Knuckles
Courtesy of FORD MOTOR CO.
NOTE: RH side shown in illustration, LH side similar.
34. Using the Front Wheel Hub Remover, separate the front halfshafts from the wheel hubs.
Fig 30: Separating Halfshaft From Wheel Hub Using Special Tool (205-D070)
Courtesy of FORD MOTOR CO.
35. Remove the RH halfshaft bearing support bracket nuts and the RH halfshaft.
Fig 31: Identifying Nuts
Courtesy of FORD MOTOR CO.
36. Inspect the halfshaft hub for wear or damage and install a new 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 32: Identifying Differential Side Gear Splines, Halfshaft Bushing & Differential Seal
Courtesy of FORD MOTOR CO.
37. Using the Slide Hammer, Halfshaft Remover and Halfshaft (Plate) Remover, remove the LH halfshaft.
Fig 33: Removing Halfshaft Using Special Tools (100-001), (205-241) & (205-290)
Courtesy of FORD MOTOR CO.
38. Inspect the halfshaft hub for wear or damage and install a new 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 34: Identifying Differential Side Gear Splines, Halfshaft Bushing & Differential Seal
Courtesy of FORD MOTOR CO.
39. Remove the Y-pipe nuts and disconnect the exhaust hanger.
    • Discard the gasket and nuts.
Fig 35: Identifying Nuts And Gasket
Courtesy of FORD MOTOR CO.
40. Remove the nuts and the Y-pipe assembly.
    • Discard the nuts.
Fig 36: Locating Exhaust Flexible Pipe, Y-Pipe & Nuts
Courtesy of FORD MOTOR CO.
41. Remove and discard the nuts and bolts from the steering rack. Position the steering rack aside and support it using a suitable length of mechanic's wire.
Fig 37: Locating Bolts & Nuts For Power Steering Rack
Courtesy of FORD MOTOR CO.
42. Remove and discard the sway bar bolts. Position the sway bar aside and support it using a suitable length of mechanic's wire.
Fig 38: Locating Stabilizer Bar & Bolts
Courtesy of FORD MOTOR CO.
43. Remove the bolts from the roll restrictor bracket.
Fig 39: Identifying Bolts
Courtesy of FORD MOTOR CO.

All-Wheel Drive (AWD) vehicles 

44. Index-mark the driveshaft, remove and discard the bolts. Position the driveshaft aside.
Fig 40: Identifying Bolts
Courtesy of FORD MOTOR CO.
45. Disconnect the RH catalyst monitor electrical connector.
Fig 41: Identifying RH Catalyst Monitor Electrical Connector
Courtesy of FORD MOTOR CO.
46. Remove the catalytic converter support bracket bolts.
Fig 42: Identifying Bolts
Courtesy of FORD MOTOR CO.
47. Remove the 4 RH catalytic converter nuts and the RH catalytic converter.
Fig 43: Identifying Nuts
Courtesy of FORD MOTOR CO.
48. Remove the bolts and the Power Transfer Unit (PTU) support bracket.
Fig 44: Locating Power Transfer Unit (PTU) Support Bracket & Bolts
Courtesy of FORD MOTOR CO.
NOTE: The seal deflector will be damaged during removal. Be careful not to damage the cover seal directly behind the seal deflector.
NOTE: A new halfshaft seal must be installed anytime the RH halfshaft is removed.
49. Remove the seal deflector.
Fig 45: Identifying Seal Deflector
Courtesy of FORD MOTOR CO.
50. Using the Bearing Cup Puller and Slide Hammer, remove the halfshaft seal from the PTU.
Fig 46: Removing Intermediate Shaft Seal Using Special Tools (100-001) & (308-047)
Courtesy of FORD MOTOR CO.
51. Remove the PTU bolts and the PTU.
Fig 47: Identifying PTU & Bolts
Courtesy of FORD MOTOR CO.

All vehicles 

52. Support the subframe using the Powertrain Lift.
Fig 48: Identifying Special Tool
Courtesy of FORD MOTOR CO.
NOTE: RH shown in illustration, LH similar.
53. Remove the subframe bracket-to-body bolts.
Fig 49: Identifying Bracket-To-Body Bolts
Courtesy of FORD MOTOR CO.
NOTE: RH shown in illustration, LH similar.
54. Remove the rear subframe bolts and the subframe brackets.
Fig 50: Identifying Bolt And Bracket
Courtesy of FORD MOTOR CO.
NOTE: RH shown in illustration, LH similar.
55. Remove the front subframe bolts.
Fig 51: Identifying Bolt
Courtesy of FORD MOTOR CO.
56. Remove the subframe.
57. Remove the 2 fasteners and the torque converter inspection cover.
Fig 52: Locating Oil Fasteners On Inspection Cover
Courtesy of FORD MOTOR CO.
58. Remove and discard the 3 torque converter bolts.
Fig 53: Locating Torque Converter Bolts
Courtesy of FORD MOTOR CO.
59. Remove the secondary latches from the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.
Fig 54: Locating Secondary Latches On Transmission Fluid Cooler Tubes
Courtesy of FORD MOTOR CO.
60. Using the Transmission Cooler Line Disconnect Tool, disconnect the transmission fluid cooler tubes from the transmission fluid cooler thermal bypass valve.
Fig 55: Disconnecting Transmission Cooling Tubes Using Special Tool (307-569)
Courtesy of FORD MOTOR CO.
61. Remove the transaxle support insulator through bolt.
    1. Remove the flagnut.
    2. Release the tension from the through bolt to remove it from the transaxle mount.
Fig 56: Identifying Flagnut And Through Bolt
Courtesy of FORD MOTOR CO.
62. Lower the transaxle from the mount about 50.8 mm (2 in).
63. Remove the nuts, the bolt and the transaxle support insulator bracket.
Fig 57: Identifying Bolt, Nuts And Mount Bracket
Courtesy of FORD MOTOR CO.
64. Using the Transmission Jack Adapter, support the transaxle.
Fig 58: Supporting Transaxle Using Special Tool (209-00152) & A Suitable Transmission Jack
Courtesy of FORD MOTOR CO.
65. Remove the remaining torque converter housing bolts and remove the transaxle from the vehicle.
Fig 59: Locating torque converter housing bolts
Courtesy of FORD MOTOR CO.
66. Remove the manual control lever.
Fig 60: Manual Control Lever
Courtesy of FORD MOTOR CO.
67. Remove and discard the transmission fluid cooler tube bolts.
Fig 61: Transmission Fluid Cooler Tube Bolts
Courtesy of FORD MOTOR CO.
68. Remove the 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 62: Removing Nuts & Pulling Transmission Fluid Cooler Thermal Bypass Valve & Transmission Fluid Cooler Tubes Straight Up
Courtesy of FORD MOTOR CO.
69. Inspect the transaxle case to be 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 63: Locating Transmission Fluid Cooler Tube Seals & Backing Rings
Courtesy of FORD MOTOR CO.
70. If the transaxle is to be overhauled or if installing a new or re-manufactured transaxle, carry out transmission fluid cooler backflushing and cleaning. For additional information, refer to Transmission Fluid Cooler Backflushing and Cleaning .