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Section 551 (Engine - 4.0L): Removal: Engine

WARNING: This page is about a different car, the 2004 Mercury Mountaineer and 2004 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Identifying Special Tool(s)
G03180648Courtesy of FORD MOTOR CO.

All vehicles 

CAUTION: If the supply manifold is used as a leverage device, damage can occur to the supply manifold. Care must be taken when working around the fuel supply manifold.
NOTE: Inspect the engine support insulators for wear or damage.
  1. Disconnect the fuel tube spring lock coupling. For additional information, refer to FUEL SYSTEM .
  2. Remove the nut and disconnect the ground wire.
    Fig 2: Removing Nut And Disconnect Ground Wire
    G03180649Courtesy of FORD MOTOR CO.
  3. Disconnect the electrical connector and detach the wiring harness retainers.
    Fig 3: Disconnecting Electrical Connector And Detach Wiring Harness Retainers
    G03180650Courtesy of FORD MOTOR CO.
  4. Lift the cover, remove the nut and disconnect the battery cable connector.
    Fig 4: Lifting Cover Remove Nut And Disconnect Battery Cable Connector
    G03180651Courtesy of FORD MOTOR CO.
  5. Drain the cooling system. For additional information, refer to ENGINE COOLING .
  6. Recover the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM .
  7. Disconnect the windshield washer hose.
    Fig 5: Disconnecting Windshield Washer Hose
    G03180652Courtesy of FORD MOTOR CO.
    8. NOTE: Mark the hinge locations for installation reference.
    Fig 6: Removing Four Bolts And Hood
    G03180653Courtesy of FORD MOTOR CO.
  8. Remove the four bolts and the hood.
  9. Remove the cooling fan and shroud. For additional information, refer to ENGINE COOLING .
  10. Remove the power steering pump pulley. For additional information, refer to STEERING SYSTEM .
  11. Remove the air cleaner outlet pipe. For additional information, refer to INTAKE AIR, FUEL CHARGING, STARTING AND ENGINE ELECTRONICS - 4.0L SOHC .
  12. Disconnect the mass air flow (MAF) sensor electrical connector.
    Fig 7: Disconnecting Mass Air Flow (MAF) Sensor Electrical Connector
    G03180654Courtesy of FORD MOTOR CO.
  13. Remove the air cleaner assembly.
    Fig 8: Removing Air Cleaner Assembly
    G03180655Courtesy of FORD MOTOR CO.
  14. Disconnect the powertrain control module (PCM) electrical connectors.
    Fig 9: Disconnecting Powertrain Control Module (PCM) Electrical Connectors
    G03180656Courtesy of FORD MOTOR CO.
  15. Release the fuel charging wiring harness from the clips on the bulkhead.
    Fig 10: Releasing Fuel Charging Wiring Harness From Clips On Bulkhead
    G03180657Courtesy of FORD MOTOR CO.
  16. Disconnect the transmission control wiring harness pin-type retainers from the fuel charging wiring harness.
    Fig 11: Disconnecting Transmission Control Wiring Harness Pin-Type Retainers From Fuel Charging Wiring Harness
    G03180658Courtesy of FORD MOTOR CO.
  17. Disconnect the evaporative emissions (EVAP) return tube and position it aside.
    Fig 12: Disconnecting Evaporative Emissions (EVAP) Return Tube And Position
    G03180659Courtesy of FORD MOTOR CO.
  18. Disconnect the vacuum hose.
    Fig 13: Disconnecting Vacuum Hose
    G03180660Courtesy of FORD MOTOR CO.
  19. Remove the bolt from the engine ground wire.
    Fig 14: Removing Bolt From Engine Ground Wire
    G03180661Courtesy of FORD MOTOR CO.
  20. Disconnect the vacuum hose and the heater hose.
    Fig 15: Disconnecting Vacuum Hose And Heater Hose
    G03180662Courtesy of FORD MOTOR CO.
  21. Disconnect the upper radiator hose and the heater hose.
    Fig 16: Disconnecting Upper Radiator Hose And Heater Hose
    G03180663Courtesy of FORD MOTOR CO.
  22. Remove the bolts and position the heater hoses and bracket aside.
    Fig 17: Removing Bolts And Position Heater Hoses And Bracket
    G03180664Courtesy of FORD MOTOR CO.
  23. Disconnect the lower radiator hose at the coolant pump.
    1. Release the clamp.
    2. Disconnect the radiator hose.
    Fig 18: Disconnecting Radiator Hose
    G03180665Courtesy of FORD MOTOR CO.
  24. Disconnect the coolant hoses from the degas bottle.
    Fig 19: Disconnecting Coolant Hoses From Degas Bottle
    G03180666Courtesy of FORD MOTOR CO.
    25. NOTE: Cover the accumulator opening to prevent contamination.
    Fig 20: Removing Nut And Disconnect The A/C Tube From Accumulator
    G03180667Courtesy of FORD MOTOR CO.
  25. Remove the nut and disconnect the A/C tube from the accumulator.
    • Discard the O-ring seal.
  26. Remove the nut and disconnect the A/C tube from the condenser.
    Fig 21: Removing Nut And Disconnect A/C Tube From Condenser
    G03180668Courtesy of FORD MOTOR CO.
  27. Disconnect the vacuum hoses.
    Fig 22: Disconnecting Vacuum Hoses
    G03180669Courtesy of FORD MOTOR CO.
  28. Disconnect the A/C high-pressure cut-off switch electrical connector.
    Fig 23: Disconnecting A/C High-Pressure Cut-Off Switch Electrical Connector
    G03180670Courtesy of FORD MOTOR CO.
  29. Remove the nut and disconnect the A/C tube from the condenser.
    • Discard the O-ring seal.
    Fig 24: Discarding O-Ring Seal
    G03180671Courtesy of FORD MOTOR CO.
  30. Disconnect the A/C tube from the retainer.
    Fig 25: Disconnecting A/C Tube From Retainer
    G03180672Courtesy of FORD MOTOR CO.
  31. Remove the EGR valve tube.
    1. Disconnect the EGR tube fittings.
    2. Remove the EGR tube.
    Fig 26: Removing EGR Tube
    G03180673Courtesy of FORD MOTOR CO.
  32. Remove the starter. For additional information, refer to INTAKE AIR, FUEL CHARGING, STARTING AND ENGINE ELECTRONICS - 4.0L SOHC .
  33. Remove the pushpins.
    Fig 27: Removing Pushpins
    G03180674Courtesy of FORD MOTOR CO.
  34. Remove the nut and detach the battery cable retainer bracket.
    Fig 28: Removing Nut And Detach Battery Cable Retainer Bracket
    G03180675Courtesy of FORD MOTOR CO.

    35. 4x4 vehicles 

  35. Install a suitable jack stand under the transfer case.
    Fig 29: Installing A Suitable Jack Stand Under Transfer Case
    G03180676Courtesy of FORD MOTOR CO.

    36. 4x2 vehicles 

    WARNING: Secure the transmission to the transmission jack with a safety chain. Failure to follow these instructions can result in personal injury.
    Fig 30: Identifying Transmission With A Transmission Jack
    G03180677Courtesy of FORD MOTOR CO.
  36. Support the transmission with a transmission jack.

    37. All vehicles 

  37. Remove the two bolts and position the RH heat shield aside.
    Fig 31: Removing Two Bolts And Position RH Heat Shield
    G03180678Courtesy of FORD MOTOR CO.
    38. NOTE: LH shown, RH similar.
    Fig 32: Disconnecting Two Heated Oxygen Sensor (Ho2S) Electrical Connectors
    G03180679Courtesy of FORD MOTOR CO.
  38. Disconnect the two heated oxygen sensor (HO2S) electrical connectors.
    39. NOTE: RH shown, LH similar.
    Fig 33: Disconnecting Two Catalyst Monitor Sensor Electrical Connectors
    G03180680Courtesy of FORD MOTOR CO.
  39. Disconnect the two catalyst monitor sensor electrical connectors.
  40. Remove the RH heat shield bolts.
    Fig 34: Removing RH Heat Shield Bolts
    G03180681Courtesy of FORD MOTOR CO.
  41. Remove the RH heat shield bolt and remove the heat shield.
    Fig 35: Removing RH Heat Shield Bolt And Remove Heat Shield
    G03180682Courtesy of FORD MOTOR CO.
  42. Remove the LH heat shield bolt.
    Fig 36: Removing LH Heat Shield Bolt
    G03180683Courtesy of FORD MOTOR CO.
  43. Remove the two nuts and the plastic shield on the right side of the crossmember.
    Fig 37: Removing Two Nuts And Plastic Shield On Right Side Of Crossmember
    G03180684Courtesy of FORD MOTOR CO.
    44. NOTE: RH shown, LH similar.
    Fig 38: Removing Four Upper Crossmember Bolts
    G03180685Courtesy of FORD MOTOR CO.
  44. Remove the four upper crossmember bolts.
    45. NOTE: RH shown, LH similar.
    Fig 39: Removing Four Lower Crossmember
    G03180686Courtesy of FORD MOTOR CO.
  45. Remove the four lower crossmember bolts.

    46. 4x2 vehicles 

  46. Remove the bolts and cable bracket from the transmission.
    Fig 40: Removing Bolts And Cable Bracket From Transmission
    G03180687Courtesy of FORD MOTOR CO.

    47. All vehicles 

  47. Remove the transmission support insulator nuts and remove the crossmember.
    Fig 41: Removing Transmission Support Insulator Nuts
    G03180688Courtesy of FORD MOTOR CO.
  48. Remove the bolts, springs, flag nuts and separate the muffler from the converter.
    • Discard the gasket.
    • Discard the flag nuts.
    Fig 42: Removing Bolts Springs Flag Nuts And Separate Muffler From Converter
    G03180689Courtesy of FORD MOTOR CO.
    49. NOTE: LH shown, RH similar.
    Fig 43: Removing Four Converter-To-Manifold
    G03180690Courtesy of FORD MOTOR CO.
  49. Remove the four converter-to-manifold nuts.
    50. NOTE: The assistance of another technician may be required.
    Fig 44: Removing Transmission-Mounted Exhaust Hanger
    G03180691Courtesy of FORD MOTOR CO.
  50. Remove the transmission-mounted exhaust hanger, the three-way converter system and the RH heat shield.
    1. Remove the bolt and the converter assembly.
    2. If required, remove the second bolt and mount.
  51. Disconnect the shift cable and remove the bracket.
    Fig 45: Disconnecting Shift Cable And Bracket
    G03180692Courtesy of FORD MOTOR CO.
  52. Position the manual shift lever out of PARK.
    Fig 46: Positioning Manual Shift Lever Out Of Park
    G03180693Courtesy of FORD MOTOR CO.

    53. 4x4 vehicles 

  53. Index-mark the front axle pinion flange and the front driveshaft.
    Fig 47: Identifying Index-Mark Front Axle Pinion Flange And Front Driveshaft
    G03180694Courtesy of FORD MOTOR CO.
  54. Index-mark the front output shaft assembly and the front driveshaft constant velocity (CV) joint.
    Fig 48: Identifying Index-Mark Front Output Shaft Assembly
    G03180695Courtesy of FORD MOTOR CO.
  55. Remove and discard the bolts and washers.
    Fig 49: Removing And Discard Bolts And Washers
    G03180696Courtesy of FORD MOTOR CO.
  56. Remove and discard the bolts and universal joint retainers.
    Fig 50: Removing And Discard Bolts And Universal Joint Retainers
    G03180697Courtesy of FORD MOTOR CO.
    57. CAUTION: Always disconnect the front driveshaft from the transfer case first. Otherwise, the weight of the driveshaft can pinch the boot and cause the boot to tear.
    CAUTION: Tape the bearing cups to the driveshaft to prevent them from falling off the spider.
    Fig 51: Removing Front Driveshaft
    G03180698Courtesy of FORD MOTOR CO.
  57. Remove the front driveshaft.

    58. All vehicles 

    NOTE: The axle pinion flange is shown, the transfer case output flange, if equipped, is similar.
    Fig 52: Identifying Transfer Case Rear Output Flange For Assembly
    G03180699Courtesy of FORD MOTOR CO.
  58. Mark the driveshaft flange to the rear axle pinion flange, and if equipped, the transfer case rear output flange for assembly reference.
  59. Remove the four rear axle flange bolts.
    Fig 53: Removing Four Rear Axle Flange Bolts
    G03180700Courtesy of FORD MOTOR CO.

    60. 4x2 vehicles 

  60. Index-mark the driveshaft at the six o'clock position.
    Fig 54: Identifying Index-Mark Driveshaft At Six O'Clock Position
    G03180701Courtesy of FORD MOTOR CO.

    61. 4x4 vehicles 

  61. Remove the four transfer case flange bolts.
    Fig 55: Removing Four Transfer Case Flange Bolts
    G03180702Courtesy of FORD MOTOR CO.

    62. All vehicles 

    CAUTION: The driveshaft flange fits tightly on the rear axle pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft flange from the pinion flange.
    NOTE: Do not rotate the driveshaft.
    Fig 56: Disconnecting Driveshaft Flange And Driveshaft
    G03180703Courtesy of FORD MOTOR CO.
  62. Using a suitable tool as shown, disconnect the driveshaft flange and remove the driveshaft.

    63. 4x2 vehicles 

  63. Index-mark the transmission output shaft at the six o'clock position.
    1. Pull the seal away from the transmission output shaft.
    2. Mark the output shaft at the six o'clock position.
    Fig 57: Pulling Seal Away From Transmission Output Shaft
    G03180704Courtesy of FORD MOTOR CO.

    64. All vehicles 

  64. Disconnect the RH catalyst monitor connector and the fuel tubes from the bracket.
    Fig 58: Disconnecting RH Catalyst Monitor Connector And Fuel Tubes From Bracket
    G03180705Courtesy of FORD MOTOR CO.
  65. Disconnect the RH HO2S electrical connector from the transmission.
    Fig 59: Disconnecting RH HO2S Electrical Connector From Transmission
    G03180706Courtesy of FORD MOTOR CO.
  66. If equipped, disconnect the shift motor electrical connector.
    Fig 60: Disconnecting Shift Motor Electrical Connector
    G03180707Courtesy of FORD MOTOR CO.
  67. Disconnect the LH HO2S electrical connector retainer and the harness clip from the transmission.
    Fig 61: Disconnecting LH Ho2S Electrical Connector Retainer And Harness Clip From Transmission
    G03180708Courtesy of FORD MOTOR CO.
  68. Disconnect the LH catalyst monitor connector from the transmission.
    Fig 62: Disconnecting LH Catalyst Monitor Connector From Transmission
    G03180709Courtesy of FORD MOTOR CO.
    69. NOTE: Make an identifying mark on the nut, stud and flexplate to allow for correct installation.
    Fig 63: Rotating Crankshaft To Access All Nuts
    G03180710Courtesy of FORD MOTOR CO.
  69. Remove the four torque converter nuts.
    • Rotate the crankshaft to access all the nuts.
  70. Move the rubber boot back to gain access to the connector.
    Fig 64: Moving Rubber Boot Back To Gain Access To Connector
    G03180711Courtesy of FORD MOTOR CO.
  71. Disconnect the digital transmission range sensor.
    Fig 65: Disconnecting Digital Transmission Range Sensor
    G03180712Courtesy of FORD MOTOR CO.
  72. Disconnect the electrical connectors.
    Fig 66: Disconnecting Electrical Connectors
    G03180713Courtesy of FORD MOTOR CO.
    73. NOTE: Clean the area around the connector to prevent contamination of the solenoid body connector.
    Fig 67: Removing Screw And Disconnect Solenoid Body Electrical Connector
    G03180714Courtesy of FORD MOTOR CO.
  73. Remove the screw and disconnect the solenoid body electrical connector.
  74. Disconnect the harness retainers.
    Fig 68: Disconnecting Harness Retainers
    G03180715Courtesy of FORD MOTOR CO.
    75. CAUTION: Do not damage the cooler tubes. Hold the transmission case fitting with a wrench.
    Fig 69: Disconnecting Transmission Cooler Tubes
    G03180716Courtesy of FORD MOTOR CO.
  75. Disconnect the transmission cooler tubes.
  76. Disconnect the transmission cooler tubes and allow them to drain into a suitable container.
    Fig 70: Disconnecting Transmission Cooler Tubes
    G03180717Courtesy of FORD MOTOR CO.
  77. Remove the nut and the cooler tubes and bracket.
    Fig 71: Removing Nut And Cooler Tubes And Bracket
    G03180718Courtesy of FORD MOTOR CO.

    78. 4x4 vehicles 

    WARNING: Secure the transmission to the jack with a safety chain. Failure to follow these instructions can result in personal injury.
    Fig 72: Removing Transmission With A Transmission Jack
    G03180719Courtesy of FORD MOTOR CO.
  78. Support the transmission with a transmission jack.
  79. Remove the jack stand from the transfer case.
    Fig 73: Removing Jack Stand From Transfer Case
    G03180720Courtesy of FORD MOTOR CO.

    80. All vehicles 

  80. Remove the eight engine-to-transmission retaining bolts.
    Fig 74: Removing Eight Engine-To-Transmission Retaining
    G03180721Courtesy of FORD MOTOR CO.
  81. Remove the transmission.
  82. Install the special tool.
    Fig 75: Identifying Special Tool
    G03180722Courtesy of FORD MOTOR CO.
  83. Disconnect the power steering return hose and allow it to drain into a suitable container.
    Fig 76: Disconnecting Power Steering Return Hose
    G03180723Courtesy of FORD MOTOR CO.
  84. Drain the engine oil and remove the oil filter.
    • Install the drain plug when finished.
    Fig 77: Draining Engine Oil
    G03180724Courtesy of FORD MOTOR CO.
  85. Remove the LH engine support insulator bolt.
    Fig 78: Removing LH Engine Support Insulator Bolt
    G03180725Courtesy of FORD MOTOR CO.
  86. Lower the vehicle.
  87. Remove the bolt and power steering tube support bracket.
    Fig 79: Removing Bolt And Power Steering Tube Support Bracket
    G03180726Courtesy of FORD MOTOR CO.
  88. Disconnect the power steering pressure (PSP) tube.
    • Remove and discard the O-ring seal.
    Fig 80: Removing And Discard O-Ring Seal
    G03180727Courtesy of FORD MOTOR CO.
  89. Remove the RH engine support insulator nuts.
    Fig 81: Removing RH Engine Support Insulator Nuts
    G03180728Courtesy of FORD MOTOR CO.
  90. Remove the bolts and the LH radiator support bracket.
    Fig 82: Removing Bolts And LH Radiator Support Bracket
    G03180729Courtesy of FORD MOTOR CO.
  91. Remove the bolts and the RH radiator support bracket.
    Fig 83: Removing Bolts And RH Radiator Support Bracket
    G03180730Courtesy of FORD MOTOR CO.
  92. Remove the radiator and A/C condenser as an assembly.
    Fig 84: Removing Radiator And A/C Condenser As Assembly
    G03180731Courtesy of FORD MOTOR CO.
  93. Install the right side lifting bracket.
    Fig 85: Installing Right Side Lifting Bracket
    G03180732Courtesy of FORD MOTOR CO.
  94. Install the left side lifting bracket.
    Fig 86: Installing Left Side Lifting Bracket
    G03180733Courtesy of FORD MOTOR CO.
  95. Attach a floor crane to the spreader bar and remove the engine.
    Fig 87: Attaching A Floor Crane To Spreader Bar And Remove Engine
    G03180734Courtesy of FORD MOTOR CO.
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