removal - about us | justanswerww2.justanswer.com/uploads/kennyz1963/2011-10-02_035929_1.pdfoct 02,...

303-01B-1 303-01B-1Engine — 4.6L (2V)

REMOVAL

2. Disconnect the fuel tube spring coupling. ForEngineadditional information, refer to Fuel Lines andFuel Filter — 4.6L (2V) in Section 310-00.Special Tool(s)

Spreader Bar 3. Remove the nut and disconnect the ground303-D089 (D93P-6001-A3) or wire.equivalent

Holding Wrench, Fan Pulley303-239 (T84T-6312-C)

Wrench, Fan Clutch Nut303-240 (T84T-6312-D)

4. Disconnect the electrical connector and detachthe wiring harness pin-type retainers.

Disconnect Tool, Transmission307-441

Lifting Bracket Set, Engine303-D074 (D91P-6001-A) orequivalent

5. Lift the cover, remove the nut and disconnectthe wiring harness terminals.

All vehicles

NOTE: Inspect the engine support insulators forwear or damage.

1. With the vehicle in NEUTRAL, position it on ahoist. For additional information, refer toSection 100-00.

Copyright 2003, Ford Motor CompanyLast updated: 2/19/2004 2004 Explorer/Mountaineer, 10/2003

303-01B-2 303-01B-2Engine — 4.6L (2V)

REMOVAL (Continued)

6. Drain the cooling system. For additionalinformation, refer to Section 303-03.

7. Recover the air conditioning system. Foradditional information, refer to Section 412-00.

8. Disconnect the windshield washer hose.

11. Disconnect the mass air flow (MAF) electricalconnector.

9. NOTE: Mark the hinge locations forinstallation reference.

Remove the four bolts and the hood.

12. Remove the air cleaner assembly.

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.

2004 Explorer/Mountaineer, 10/2003

303-01B-3 303-01B-3Engine — 4.6L (2V)

REMOVAL (Continued)

13. Remove the upper radiator appearance cover. 16. Squeeze the clamp and disconnect the heaterhose.

14. Squeeze the clamps and disconnect the upperradiator and heater hoses. 17. Disconnect the A/C pressure switch electrical

connector.

15. Squeeze the clamps and disconnect the upperradiator and degas vent hoses. 18. Remove the nut, and disconnect the manifold

and tube assembly from the condenser.• Remove the upper radiator hose.


303-01B-4 303-01B-4Engine — 4.6L (2V)

REMOVAL (Continued)

19. Detach the A/C tube from the retainers and 22. NOTE: RH shown, LH similar.position the tube aside. NOTE: Some vehicles are equipped with only

one assembly screw.

Remove the two bolts and the screw(s). Discardthe screws.

20. NOTE: Cover the accumulator with a suitablecap or tape to prevent contamination.

Remove the nut and disconnect the manifoldtube from the accumulator. If equipped, remove 23. Remove the upper fan shroud.the nut and disconnect the auxiliary A/C tube.

24. Using the special tools, remove the cooling fan.21. Remove the nut and disconnect the evaporator

tube from the condenser.


303-01B-5 303-01B-5Engine — 4.6L (2V)

REMOVAL (Continued)

25. Remove the heater control valve bracket bolt.

29. Remove the bolts and position aside the cablebracket.

26. Disconnect the heater control vacuum supplyhose.

30. Install the special tool.

27. Disconnect the brake booster vacuum hose.

28. Disconnect the hoses from the evaporativeemissions (EVAP) canister purge valve.


303-01B-6 303-01B-6Engine — 4.6L (2V)

REMOVAL (Continued)

31. Drain the engine oil. 34. Remove the bolts and the lower fan shroud.

• Install the drain plug when finished.

35. Remove the lower air deflector pin-typeretainers.32. Squeeze the clamp and disconnect the coolant

hose from the radiator. Detach the hose fromthe retainer and position the hose aside.

36. Using the special tool, disconnect the coolertubes from the cooler.

33. Squeeze the clamp and disconnect the lower • Drain the fluid into a suitable container.radiator hose.


303-01B-7 303-01B-7Engine — 4.6L (2V)

REMOVAL (Continued)

37. Remove the two bolts and the LH radiatorsupport bracket.

4x2 vehicles

41. WARNING: Secure the transmission to38. Remove the two bolts and the RH radiator

the transmission jack with a safety chain.support bracket.

Failure to follow these instructions can resultin personal injury.

Support the transmission with a transmissionjack.

39. Remove the radiator and A/C condenser as anassembly.

All vehicles

42. Remove the bolts and position the RH heatshield aside.

4x4 vehicles

40. Position a suitable jack under the transfer case.


303-01B-8 303-01B-8Engine — 4.6L (2V)

REMOVAL (Continued)

43. NOTE: LH shown, RH similar. 46. Remove the bolt and the RH heat shield.

Disconnect both heated oxygen sensor (HO2S)electrical connectors.

47. Remove the LH heat shield bolt.

44. NOTE: RH shown, LH similar.

Disconnect both catalyst monitor sensorelectrical connectors.

48. Remove the two nuts and the plastic shield onthe RH side of the crossmember.

45. Remove the RH heat shield bolts.


303-01B-9 303-01B-9Engine — 4.6L (2V)

REMOVAL (Continued)

49. NOTE: RH side shown, LH side similar.

Remove the four crossmember upper bolts.

53. Remove the bolts, the nuts and the springs, anddisconnect the muffler from the dual converterY-pipe. Remove and discard the gasket.

50. NOTE: RH side shown, LH side similar.

Remove the four crossmember lower bolts.

54. Using a suitable jack stand, support the dualconverter Y-pipe.

4x2 vehicles

51. Remove the bolts and the bracket.

All vehicles

52. Remove the nuts and the crossmember.


303-01B-10 303-01B-10Engine — 4.6L (2V)

REMOVAL (Continued)

55. Remove the bolts and the transmission rearmount.

4x4 vehicles

59. Mark the front axle pinion flange and the front56. Remove the four exhaust manifold-to-dual driveshaft for assembly reference.

converter Y-pipe nuts. Remove the jack standthe dual converter Y-pipe and the heat shields.

60. Mark the front output shaft assembly and thefront driveshaft CV joint for assembly

57. Disconnect the shift cable and remove the bolts reference.and the bracket.

58. Position the manual shift lever out of the parkposition.


303-01B-11 303-01B-11Engine — 4.6L (2V)

REMOVAL (Continued)

All vehicles61. Remove and discard the bolts and washers.

64. NOTE: The axle pinion flange is shown, thetransfer case output flange, if equipped, issimilar.

Mark the driveshaft flange to the rear axlepinion flange, and if equipped, the transfer caserear output flange for assembly reference.

62. Remove and discard the bolts and the universaljoint retainers.

65. Remove the four pinion flange bolts.

63. CAUTION: Always disconnect thefront driveshaft from the transfer case first.The weight of the driveshaft can pinch theboot, causing the boot to tear.

CAUTION: Tape the bearing cups tothe driveshaft to prevent them from fallingoff of the spider.

Remove the front driveshaft.


303-01B-12 303-01B-12Engine — 4.6L (2V)

REMOVAL (Continued)

4x4 vehicles

66. Remove the four transfer case flange bolts.

69. NOTE: Clean the area around the connector toprevent contamination of the solenoid bodyconnector.

Remove the screw and disconnect the solenoidAll vehicles body electrical connector.

67. CAUTION: The driveshaft flange fitstightly on the rear axle pinion flange pilot.Never hammer on the driveshaft or any of itscomponents to disconnect the driveshaftflange from the pinion flange. Damage to thedriveshaft can occur.

NOTE: Use a suitable plug to preventtransmission fluid loss on two wheel drivevehicles.

Using a suitable tool as shown, disconnect thedriveshaft flange from the rear axle pinionflange and remove the driveshaft.

70. NOTE: Move the rubber boot back to gainaccess to the connector.

Disconnect the transmission range sensorelectrical connector.

68. Disconnect the turbine shaft speed (TSS)sensor, the output shaft speed (OSS) sensor, andthe intermediate shaft speed (ISS) sensorelectrical connectors.


303-01B-13 303-01B-13Engine — 4.6L (2V)

REMOVAL (Continued)

71. Detach the wiring harness retainers.

4x4 vehicles

72. NOTE: RH shown, LH similar. 75. If equipped, disconnect the shift motor electricalconnector and detach the harness pin-typeDetach both heated oxygen sensor (HO2S)retainer(s).electrical connector retainers from the

transmission.

76. WARNING: Secure the transmission to73. Disconnect the LH catalyst monitor sensor the jack with a safety chain. Failure to follow

electrical retainer from the transmission. these instructions can result in personalinjury.

Support the transmission with a transmissionjack.

74. Disconnect the RH catalyst monitor sensorelectrical connector retainer and the fuel tubesfrom the bracket.


303-01B-14 303-01B-14Engine — 4.6L (2V)

REMOVAL (Continued)

77. Remove the jack stand from the transfer case. 80. Disconnect the starter wiring.

1 Remove the nut and disconnect the batterypositive cable.

2 Remove the nut and disconnect the startersolenoid wire.

All vehicles

78. NOTE: RH shown, LH similar.

Remove the four bolts and the frontcrossmember. 81. Remove the three bolts and the starter.

79. Remove the cover. 82. Remove the bolts and the cover.


303-01B-15 303-01B-15Engine — 4.6L (2V)

REMOVAL (Continued)

83. Remove the access cover. 86. Remove the seven engine-to-transmission bolts.

84. NOTE: Mark one stud and the flexplate for 87. Using a suitable wooden block, support theassembly reference. front of the engine against the front

crossmember.Remove the four torque converter nuts.• Position the wooden block as shown.• Rotate the crankshaft using the crankshaft

pulley bolt.

88. Lower the transmission and, if equipped, thetransfer case.

85. CAUTION: Use a wrench to hold thetransmission case fitting, to prevent damage 89. Disconnect the LH HO2S wiring harness fromto the cooler tubes. the retainer.Disconnect the cooler tubes.


303-01B-16 303-01B-16Engine — 4.6L (2V)

REMOVAL (Continued)

90. Remove the nut and the cooler tube bracket. 93. Remove the nut and washer from the RH motormount.

91. Disconnect the power steering return hose.94. Remove the bolt from the LH motor mount.• Drain the fluid into a suitable container.

95. Disconnect the fuel charging wiring harness92. Disconnect the power steering pressure (PSP)electrical connectors.hose.


303-01B-17 303-01B-17Engine — 4.6L (2V)

REMOVAL (Continued)

96. NOTE: If necessary, separate the tape from the 99. Install the special tool.transmission harness.

Disconnect the fuel charging wiring harnesspin-type retainer.

100. Support the fuel hose with a wire tie ormechanic’s wire.

97. Remove the harness retaining clip from theground stud bolt.

101. Attach the special tool to a floor crane and theengine, and remove the engine from thevehicle.

98. Remove the stud bolt and disconnect the groundstrap.


removal - about us | justanswerww2.justanswer.com/uploads/kennyz1963/2011-10-02_035929_1.pdfoct 02,...

Documents