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Section 602 (Engine - 4.6L): 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 Service Tool
G03181263Courtesy of FORD MOTOR CO.
NOTE: Inspect the engine support insulators for wear or damage.

    All vehicles 

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Disconnect the fuel tube spring coupling. For additional information, refer to FUEL SYSTEM .
  3. Remove the nut and disconnect the ground wire.
    Fig 2: Disconnecting Ground Wire
    G03181264Courtesy of FORD MOTOR CO.
  4. Disconnect the electrical connector and detach the wiring harness pin-type retainers.
    Fig 3: Disconnecting Electrical Connector And Wiring Harness Pin-Type Retainers
    G03181265Courtesy of FORD MOTOR CO.
  5. Lift the cover, remove the nut and disconnect the wiring harness terminals.
    Fig 4: Disconnecting Wiring Harness Terminals
    G03181266Courtesy of FORD MOTOR CO.
  6. Drain the cooling system. For additional information, refer to ENGINE COOLING .
  7. Recover the air conditioning system. For additional information, refer to CLIMATE CONTROL SYSTEM .
  8. Disconnect the windshield washer hose.
    Fig 5: Disconnecting Windshield Washer Hose
    G03181267Courtesy of FORD MOTOR CO.
    9. NOTE: Mark the hinge locations for installation reference.
    Fig 6: Removing Bolts And Hood
    G03181268Courtesy of FORD MOTOR CO.
  9. Remove the four bolts and the hood.
  10. Remove the air cleaner outlet tube.
    1. Loosen the clamp.
    2. Disconnect the hose.
    3. Loosen the clamp.
    4. Remove the air cleaner outlet tube.
    Fig 7: Removing Air Cleaner Outlet Tube
    G03181269Courtesy of FORD MOTOR CO.
  11. Disconnect the mass air flow (MAF) electrical connector.
    Fig 8: Disconnecting Mass Air Flow (MAF) Electrical Connector
    G03181270Courtesy of FORD MOTOR CO.
  12. Remove the air cleaner assembly.
    Fig 9: Removing Air Cleaner Assembly
    G03181271Courtesy of FORD MOTOR CO.
  13. Remove the upper radiator appearance cover.
    Fig 10: Removing Upper Radiator Appearance Cover
    G03181272Courtesy of FORD MOTOR CO.
  14. Squeeze the clamps and disconnect the upper radiator and heater hoses.
    Fig 11: Disconnecting Upper Radiator And Heater Hoses
    G03181273Courtesy of FORD MOTOR CO.
  15. Squeeze the clamps and disconnect the upper radiator and degas vent hoses.
    • Remove the upper radiator hose.
    Fig 12: Removing Upper Radiator Hose
    G03181274Courtesy of FORD MOTOR CO.
  16. Squeeze the clamp and disconnect the heater hose.
    Fig 13: Disconnecting Heater Hose
    G03181275Courtesy of FORD MOTOR CO.
  17. Disconnect the A/C pressure switch electrical connector.
    Fig 14: Disconnecting A/C Pressure Switch Electrical Connector
    G03181276Courtesy of FORD MOTOR CO.
  18. Remove the nut, and disconnect the manifold and tube assembly from the condenser.
    Fig 15: Removing Manifold And Tube Assembly From The Condenser
    G03181277Courtesy of FORD MOTOR CO.
  19. Detach the A/C tube from the retainers and position the tube aside.
    Fig 16: Disconnecting A/C Tube From Retainers And Position Tube
    G03181278Courtesy of FORD MOTOR CO.
    20. NOTE: Cover the accumulator with a suitable cap or tape to prevent contamination.
    Fig 17: Disconnecting Auxiliary A/C Tube
    G03181279Courtesy of FORD MOTOR CO.
  20. Remove the nut and disconnect the manifold tube from the accumulator. If equipped, remove the nut and disconnect the auxiliary A/C tube.
  21. Remove the nut and disconnect the evaporator tube from the condenser.
    Fig 18: Disconnecting Evaporator Tube From Condenser
    G03181280Courtesy of FORD MOTOR CO.
    22. NOTE: RH shown, LH similar.
    NOTE: Some vehicles are equipped with only one assembly screw.
    Fig 19: Locating Bolts And Screws
    G03181281Courtesy of FORD MOTOR CO.
  22. Remove the two bolts and the screw(s). Discard the screws.
  23. Remove the upper fan shroud.
    Fig 20: Removing Upper Fan Shroud
    G03181282Courtesy of FORD MOTOR CO.
  24. Using the special tools, remove the cooling fan.
    Fig 21: Removing Cooling Fan
    G03181283Courtesy of FORD MOTOR CO.
  25. Remove the heater control valve bracket bolt.
    Fig 22: Removing Heater Control Valve Bracket Bolt
    G03181284Courtesy of FORD MOTOR CO.
  26. Disconnect the heater control vacuum supply hose.
    Fig 23: Disconnecting Heater Control Vacuum Supply Hose
    G03181285Courtesy of FORD MOTOR CO.
  27. Disconnect the brake booster vacuum hose.
    Fig 24: Disconnecting Brake Booster Vacuum Hose
    G03181286Courtesy of FORD MOTOR CO.
  28. Disconnect the hoses from the evaporative emissions (EVAP) canister purge valve.
    Fig 25: Disconnecting Hoses From Evaporative Emissions (EVAP) Canister Purge Valve
    G03181287Courtesy of FORD MOTOR CO.
  29. Remove the bolts and position aside the cable bracket.
    Fig 26: Removing Cable Bracket
    G03181288Courtesy of FORD MOTOR CO.
  30. Install the special tool.
    Fig 27: Installing Special Tool
    G03181289Courtesy of FORD MOTOR CO.
  31. Drain the engine oil.
    • Install the drain plug when finished.
    Fig 28: Installing Rain Plug
    G03181290Courtesy of FORD MOTOR CO.
  32. Squeeze the clamp and disconnect the coolant hose from the radiator. Detach the hose from the retainer and position the hose aside.
    Fig 29: Disconnecting Coolant Hose From Radiator
    G03181291Courtesy of FORD MOTOR CO.
  33. Squeeze the clamp and disconnect the lower radiator hose.
    Fig 30: Disconnecting Lower Radiator Hose
    G03181292Courtesy of FORD MOTOR CO.
  34. Remove the bolts and the lower fan shroud.
    Fig 31: Removing Lower Fan Shroud
    G03181293Courtesy of FORD MOTOR CO.
  35. Remove the lower air deflector pin-type retainers.
    Fig 32: Removing Lower Air Deflector Pin-Type Retainers
    G03181294Courtesy of FORD MOTOR CO.
  36. Using the special tool, disconnect the cooler tubes from the cooler.
    • Drain the fluid into a suitable container.
    Fig 33: Disconnecting Cooler Tubes From Cooler
    G03181295Courtesy of FORD MOTOR CO.
  37. Remove the two bolts and the LH radiator support bracket.
    Fig 34: Removing LH Radiator Support Bracket
    G03181296Courtesy of FORD MOTOR CO.
  38. Remove the two bolts and the RH radiator support bracket.
    Fig 35: Removing RH Radiator Support Bracket
    G03181297Courtesy of FORD MOTOR CO.
  39. Remove the radiator and A/C condenser as an assembly.
    Fig 36: Removing Radiator And A/C Condenser
    G03181298Courtesy of FORD MOTOR CO.

    40. 4x4 vehicles 

  40. Position a suitable jack under the transfer case.
    Fig 37: Positioning Jack Under Transfer Case
    G03181299Courtesy of FORD MOTOR CO.

    41. 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 38: Positioning Jack Transmission
    G03181300Courtesy of FORD MOTOR CO.
  41. Support the transmission with a transmission jack.

    42. All vehicles 

  42. Remove the bolts and position the RH heat shield aside.
    Fig 39: Removing RH Heat Shield
    G03181301Courtesy of FORD MOTOR CO.
    43. NOTE: LH shown, RH similar.
    Fig 40: Disconnecting Heated Oxygen Sensor (HO2S) Electrical Connectors
    G03181302Courtesy of FORD MOTOR CO.
  43. Disconnect both heated oxygen sensor (HO2S) electrical connectors.
    44. NOTE: RH shown, LH similar.
    Fig 41: Disconnecting Catalyst Monitor Sensor Electrical Connectors
    G03181303Courtesy of FORD MOTOR CO.
  44. Disconnect both catalyst monitor sensor electrical connectors.
  45. Remove the RH heat shield bolts.
    Fig 42: Removing RH Heat Shield Bolts
    G03181304Courtesy of FORD MOTOR CO.
  46. Remove the bolt and the RH heat shield.
    Fig 43: Removing RH Heat Shield
    G03181305Courtesy of FORD MOTOR CO.
  47. Remove the LH heat shield bolt.
    Fig 44: Removing LH Heat Shield Bolts
    G03181306Courtesy of FORD MOTOR CO.
  48. Remove the two nuts and the plastic shield on the RH side of the crossmember.
    Fig 45: Removing Plastic Shield On RH Side Of Crossmember
    G03181307Courtesy of FORD MOTOR CO.
    49. NOTE: RH side shown, LH side similar.
    Fig 46: Removing Crossmember Upper Bolts
    G03181308Courtesy of FORD MOTOR CO.
  49. Remove the four crossmember upper bolts.
    50. NOTE: RH side shown, LH side similar.
    Fig 47: Removing Crossmember Lower Bolts
    G03181309Courtesy of FORD MOTOR CO.
  50. Remove the four crossmember lower bolts.

    51. 4x2 vehicles 

  51. Remove the bolts and the bracket.
    Fig 48: Removing Bolts And Bracket
    G03181310Courtesy of FORD MOTOR CO.

    52. All vehicles 

  52. Remove the nuts and the crossmember.
    Fig 49: Removing Crossmember
    G03181311Courtesy of FORD MOTOR CO.
  53. Remove the bolts, the nuts and the springs, and disconnect the muffler from the dual converter Y-pipe. Remove and discard the gasket.
    Fig 50: Removing Gasket
    G03181312Courtesy of FORD MOTOR CO.
  54. Using a suitable jack stand, support the dual converter Y-pipe.
    Fig 51: Positioning Jack Under Dual Converter Y-Pipe
    G03181313Courtesy of FORD MOTOR CO.
  55. Remove the bolts and the transmission rear mount.
    Fig 52: Removing Transmission Rear Mount
    G03181314Courtesy of FORD MOTOR CO.
  56. Remove the four exhaust manifold-to-dual converter Y-pipe nuts. Remove the jack stand the dual converter Y-pipe and the heat shields.
    Fig 53: Removing Four Exhaust Manifold-To-Dual Converter Y-Pipe Nuts
    G03181315Courtesy of FORD MOTOR CO.
  57. Disconnect the shift cable and remove the bolts and the bracket.
    Fig 54: Removing Bracket
    G03181316Courtesy of FORD MOTOR CO.
  58. Position the manual shift lever out of the park position.
    Fig 55: Positioning Manual Shift Lever Out Of Park Position
    G03181317Courtesy of FORD MOTOR CO.

    59. 4x4 vehicles 

  59. Mark the front axle pinion flange and the front driveshaft for assembly reference.
    Fig 56: Locating Mark On Front Axle Pinion Flange And Front Driveshaft
    G03181318Courtesy of FORD MOTOR CO.
  60. Mark the front output shaft assembly and the front driveshaft CV joint for assembly reference.
    Fig 57: Locating Mark On Front Output Shaft Assembly And Front Driveshaft CV Joint For Assembly Reference
    G03181319Courtesy of FORD MOTOR CO.
  61. Remove and discard the bolts and washers.
    Fig 58: Removing Bolts And Washers
    G03181320Courtesy of FORD MOTOR CO.
  62. Remove and discard the bolts and the universal joint retainers.
    Fig 59: Removing Universal Joint Retainers
    G03181321Courtesy of FORD MOTOR CO.
    63. CAUTION: Always disconnect the front driveshaft from the transfer case first. The weight of the driveshaft can pinch the boot, causing the boot to tear.
    CAUTION: Tape the bearing cups to the driveshaft to prevent them from falling off of the spider.
    Fig 60: Removing Front Driveshaft
    G03181322Courtesy of FORD MOTOR CO.
  63. Remove the front driveshaft.

    64. All vehicles 

    NOTE: The axle pinion flange is shown, the transfer case output flange, if equipped, is similar.
    Fig 61: Identifying Axle Pinion Flange
    G03181323Courtesy of FORD MOTOR CO.
  64. Mark the driveshaft flange to the rear axle pinion flange, and if equipped, the transfer case rear output flange for assembly reference.
  65. Remove the four pinion flange bolts.
    Fig 62: Removing Pinion Flange Bolts
    G03181324Courtesy of FORD MOTOR CO.

    66. 4x4 vehicles 

  66. Remove the four transfer case flange bolts.
    Fig 63: Removing Transfer Case Flange Bolts
    G03181325Courtesy of FORD MOTOR CO.

    67. 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. Damage to the driveshaft can occur.
    NOTE: Use a suitable plug to prevent transmission fluid loss on two wheel drive vehicles.
    Fig 64: Removing Driveshaft
    G03181326Courtesy of FORD MOTOR CO.
  67. Using a suitable tool as shown, disconnect the driveshaft flange from the rear axle pinion flange and remove the driveshaft.
  68. Disconnect the turbine shaft speed (TSS) sensor, the output shaft speed (OSS) sensor, and the intermediate shaft speed (ISS) sensor electrical connectors.
    Fig 65: Disconnecting Turbine Shaft Speed (TSS) Sensor, The Output Shaft Speed (OSS) Sensor, And The Intermediate Shaft Speed (ISS) Sensor
    G03181327Courtesy of FORD MOTOR CO.
    69. NOTE: Clean the area around the connector to prevent contamination of the solenoid body connector.
    Fig 66: Disconnecting Solenoid Body Electrical Connector
    G03181328Courtesy of FORD MOTOR CO.
  69. Remove the screw and disconnect the solenoid body electrical connector.
    70. NOTE: Move the rubber boot back to gain access to the connector.
    Fig 67: Disconnecting Transmission Range Sensor Electrical Connector
    G03181329Courtesy of FORD MOTOR CO.
  70. Disconnect the transmission range sensor electrical connector.
  71. Detach the wiring harness retainers.
    Fig 68: Disconnecting Wiring Harness Retainers
    G03181330Courtesy of FORD MOTOR CO.
    72. NOTE: RH shown, LH similar.
    Fig 69: Disconnecting Heated Oxygen Sensor (HO2S) Electrical Connector Retainers From Transmission
    G03181331Courtesy of FORD MOTOR CO.
  72. Detach both heated oxygen sensor (HO2S) electrical connector retainers from the transmission.
  73. Disconnect the LH catalyst monitor sensor electrical retainer from the transmission.
    Fig 70: Disconnecting LH Catalyst Monitor Sensor Electrical Retainer From Transmission
    G03181332Courtesy of FORD MOTOR CO.
  74. Disconnect the RH catalyst monitor sensor electrical connector retainer and the fuel tubes from the bracket.
    Fig 71: Disconnecting RH Catalyst Monitor Sensor Electrical Connector Retainer And Fuel Tubes From Bracket
    G03181333Courtesy of FORD MOTOR CO.

    75. 4x4 vehicles 

  75. If equipped, disconnect the shift motor electrical connector and detach the harness pin-type retainer (s).
    Fig 72: Disconnecting Shift Motor Electrical Connector
    G03181334Courtesy of FORD MOTOR CO.
    76. WARNING: Secure the transmission to the jack with a safety chain. Failure to follow these instructions can result in personal injury.
    Fig 73: Supporting Transmission With Transmission Jack
    G03181335Courtesy of FORD MOTOR CO.
  76. Support the transmission with a transmission jack.
  77. Remove the jack stand from the transfer case.
    Fig 74: Removing Jack Stand From Transfer Case
    G03181336Courtesy of FORD MOTOR CO.

    78. All vehicles 

    NOTE: RH shown, LH similar.
    Fig 75: Removing Front Crossmember
    G03181337Courtesy of FORD MOTOR CO.
  78. Remove the four bolts and the front crossmember.
  79. Remove the cover.
    Fig 76: Removing Cover
    G03181338Courtesy of FORD MOTOR CO.
  80. Disconnect the starter wiring.
    1. Remove the nut and disconnect the battery positive cable.
    2. Remove the nut and disconnect the starter solenoid wire.
    Fig 77: Disconnecting Starter Solenoid Wire
    G03181339Courtesy of FORD MOTOR CO.
  81. Remove the three bolts and the starter.
    Fig 78: Removing Starter
    G03181340Courtesy of FORD MOTOR CO.
  82. Remove the bolts and the cover.
    Fig 79: Removing Bolts And Cover
    G03181341Courtesy of FORD MOTOR CO.
  83. Remove the access cover.
    Fig 80: Removing Access Cover
    G03181342Courtesy of FORD MOTOR CO.
    84. NOTE: Mark one stud and the flexplate for assembly reference.
    Fig 81: Removing Torque Converter Nuts
    G03181343Courtesy of FORD MOTOR CO.
  84. Remove the four torque converter nuts.
    • Rotate the crankshaft using the crankshaft pulley bolt.
    85. CAUTION: Use a wrench to hold the transmission case fitting, to prevent damage to the cooler tubes.
    Fig 82: Disconnecting Cooler Tubes
    G03181344Courtesy of FORD MOTOR CO.
  85. Disconnect the cooler tubes.
  86. Remove the seven engine-to-transmission bolts.
    Fig 83: Removing Engine-To-Transmission
    G03181345Courtesy of FORD MOTOR CO.
  87. Using a suitable wooden block, support the front of the engine against the front crossmember.
    • Position the wooden block as shown.
    Fig 84: Positioning Wooden Block
    G03181346Courtesy of FORD MOTOR CO.
  88. Lower the transmission and, if equipped, the transfer case.
  89. Disconnect the LH HO2S wiring harness from the retainer.
    Fig 85: Disconnecting LH HO2S Wiring Harness From Retainer
    G03181347Courtesy of FORD MOTOR CO.
  90. Remove the nut and the cooler tube bracket.
    Fig 86: Removing Cooler Tube Bracket
    G03181348Courtesy of FORD MOTOR CO.
  91. Disconnect the power steering return hose.
    • Drain the fluid into a suitable container.
    Fig 87: Disconnecting Power Steering Return Hose
    G03181349Courtesy of FORD MOTOR CO.
  92. Disconnect the power steering pressure (PSP) hose.
    Fig 88: Disconnecting Power Steering Pressure (PSP) Hose
    G03181350Courtesy of FORD MOTOR CO.
  93. Remove the nut and washer from the RH motor mount.
    Fig 89: Removing Washer From RH Motor Mount
    G03181351Courtesy of FORD MOTOR CO.
  94. Remove the bolt from the LH motor mount.
    Fig 90: Removing LH Motor Mount
    G03181352Courtesy of FORD MOTOR CO.
  95. Disconnect the fuel charging wiring harness electrical connectors.
    Fig 91: Disconnecting Fuel Charging Wiring Harness Electrical Connectors
    G03181353Courtesy of FORD MOTOR CO.
    96. NOTE: If necessary, separate the tape from the transmission harness.
    Fig 92: Disconnecting Fuel Charging Wiring Harness Pin-Type Retainer
    G03181354Courtesy of FORD MOTOR CO.
  96. Disconnect the fuel charging wiring harness pin-type retainer.
  97. Remove the harness retaining clip from the ground stud bolt.
    Fig 93: Removing Harness Retaining Clip From Ground Stud Bolt
    G03181355Courtesy of FORD MOTOR CO.
  98. Remove the stud bolt and disconnect the ground strap.
    Fig 94: Disconnecting Ground Strap
    G03181356Courtesy of FORD MOTOR CO.
  99. Install the special tool.
    Fig 95: Installing Special Tool
    G03181357Courtesy of FORD MOTOR CO.
  100. Support the fuel hose with a wire tie or mechanic's wire.
    Fig 96: Supporting Fuel Hose With Wire Tie
    G03181358Courtesy of FORD MOTOR CO.
  101. Attach the special tool to a floor crane and the engine, and remove the engine from the vehicle.
    Fig 97: Removing Engine From Vehicle
    G03181359Courtesy of FORD MOTOR CO.
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