Ford Freestar, Monterey 2004-2006

Transaxle Removal & Installation

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  1. Remove or disconnect the following:
    NOTE
    Install engine lifting eyes to support the engine during transaxle removal.



    Battery and battery tray
     
    Air cleaner assembly
     
    All transaxle electrical harnesses
     
    Transaxle shift cable from the lever by unsnapping the shift cable end from the lever ball stud
     
    Manual control lever
     
    Hood
     
    Wiper arm and pivot assembly
     
    Passenger side air intake box
     
    Air intake tube
     
    Upper radiator shield
     
    Hood latch and oil filler cap
     

  2.  
  3. Install an engine support kit and suitably support the engine.

    Click image to see an enlarged view

    Fig. Installing engine support kit-3.9L and 4.2L engines

  4.  
  5. Remove or disconnect the following:

    Transaxle filer tube
     
    Transaxle cooler lines
     
    The 2 upper transaxle-to-engine bolts
     
    Raise and support the vehicle
     
    Anti-roll bracket under the vehicle
     
    Rear transaxle support nut
     
    Transaxle fluid
     
    Catalytic converter assembly
     
    Front wheels
     

  6.  
  7. Disconnect the left and right tie rod ends from the knuckles.
  8.  
  9. Disconnect the sway bar ends from the knuckles.
  10.  
  11. Remove the left and right knuckle pinch bolts.
  12.  
  13. Remove or disconnect the following:

    Steering rack bolts
     
    Power steering hose retainers
     
    Front and rear engine mount nuts
     
    Place a jack under the subframe to support it
     
    4 subframe mounting bolts
     

  14.  
  15. Partially lower the subframe and remove the sway bar mounting bolts. Remove the sway bar.
  16.  
  17. Lower the subframe from the vehicle.
  18.  
  19. Remove or disconnect the following:

    Wire the steering rack in place
     
    Starter
     
    Halfshafts from the transaxle and support them out of the way
     
    Torque converter nuts and discard them
     
    Transaxle electrical connectors
     

  20.  
  21. Position a transaxle jack to support the transaxle and remove the transaxle mounting nuts.
  22.  
  23. Remove the oil pan-to-transaxle bolt.
  24.  
  25. Separate the transaxle from the engine block by carefully moving the transaxle rearward until enough clearance exists to remove the transaxle from the engine compartment.
  26.  

To install:


NOTE
If a different transaxle is being installed, transfer the heat shield to the new transaxle.

  1. Place the transaxle on a suitable jack and carefully raise it into position.
  2.  
  3. Install or connect the following:

    Oil pan-to-transaxle bolt, and tighten the bolt to 46 ft. lbs. (62 Nm).
     
    Engine bracket-to-transaxle bolts, and tighten the bolts to 46 ft. lbs. (62 Nm)
     
    Transaxle-to-engine bolts, and tighten the bolts to 35 ft. lbs. (47 Nm)
     
    Transaxle mounting bolts, and tighten the bolts to 46 ft. lbs. (62 Nm).
     
    Transaxle electrical connectors
     
    NEW torque converter nuts, and tighten them to 26 ft. lbs. (35 Nm)
     
    Transaxle housing cover, and tighten the bolts to 89 inch lbs. (10 Nm)
     
    Both halfshafts
     
    Starter motor, and connect the electrical harness
     
    Speedometer cable
     
    Front subframe
     
    Sway bar mounting bolts, and tighten the bolts to 46 ft. lbs. (62 Nm)
     
    The 4 subframe bolts, and tighten them to 66 ft. lbs. (90 Nm)
     
    Front and rear engine mount bolts, and tighten them to 66 ft. lbs. (90 Nm)
     
    Power steering hose retainers
     
    Steering rack bolts, and tighten them to 98 ft. lbs. 133 Nm).
     
    Left and right knuckle pinch bolts, and tighten the bolts to 46 ft. lbs. (62 Nm).
     
    Sway bar end mounting nuts, and tighten the bolts to 41 ft. lbs. (55 Nm).
     
    Tie rod end nuts, and tighten the nuts to 41 ft. lbs. (55 Nm).
     
    Catalytic converter
     
    Rear transaxle mounting nut, and tighten to 66 ft. lbs. (90 Nm)
     
    Anti-roll bracket
     
    Upper transaxle-to-engine bolts, and tighten the bolts to 46 ft. lbs. (62 Nm)
     
    Fluid cooler-to-transaxle lines
     
    Front wheels and lower the vehicle
     

  4.  
  5. Remove the engine support kit.
  6.  
  7. Install or connect the following:

    Hood latch
     
    Radiator shield
     
    Air intake tube and intake box
     
    Wiper arm and pivot assembly
     
    Hood
     
    Transaxle shift cable to the manual lever ball stud
     
    Transaxle electrical harnesses
     
    Air cleaner assembly
     
    Battery tray and battery
     

  8.  
  9. Fill the transaxle with proper amount of Mercon®V fluid.
  10.  
  11. Connect the positive, then the negative battery cable.
  12.  

 
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