Special tool
 205-857 Remover, Halfshaft |
General equipment: Powertrain Jack
NOTE: This procedure involves removing the engine and transmission.
1. Raise the vehicle.
WARNING: Ensure that the vehicle is supported securely.
2. Remove the cover and disconnect the ground cable from the battery. Refer to Procedure: Specifications (414-00 Charging System - General Information, Specifications).
3. Remove the engine trim. Refer to procedure: Engine Cover - 2.2L Duratorq - Td4 (501-05 Interior Trim, Removal and Installation).
4. Remove the pressure chamber panel. Refer to procedure: Mixing Chamber (412-01 Climate Control, Removal and Installation).
5. Remove the battery console. Refer to the procedure: Battery Installation Tray (414-01 Battery, Battery Mounting and Cables, Removal and Installation).
6. Remove the air cleaner assembly. Refer to procedure: Air Cleaner (303-12A Intake Air Distribution and Filtration - 3.2L NA - I6, Removal and Installation).
7. Drain the coolant. Refer to procedure: Draining/Filling Coolant and Bleeding the Cooling System (303-03B Engine Cooling - 2.2L Duratorq - Td4, General Procedures).
8. Remove the catalytic converter. Refer to procedure: Catalytic Converter - Vehicles Not Equipped with: Diesel Fuel Filter (309-00B Exhaust System - 2.2L Duratorq - Td4, Removal and Installation).
9. Release the refrigerant from the air conditioner. Refer to the procedure: Refrigerant Recovery, Evacuation, and Charging of the Air Conditioning (A/C) System (412-00 Climate Control System - General Information, General Procedures).
10. Remove the lower engine stabilizer bar. Refer to procedure: Lower Engine Mount Insulator (303-01A Engine - 3.2L NA - I6, Removal and Installation).
11. Remove the front subframe assembly. Refer to procedure: Front Subframe (502-00 Uni-Body, Subframe and Fastening System, Removal and Installation).
12. Pump out the working fluid from the power steering reservoir.
13. Disconnect the Engine Control Module (ECM).
14. Remove the left and right axle shafts. Special tool: 205-857
15. Remove the left axle shaft.
16. Remove the right axle shaft.
17. To gain access, move the suspension arms to the sides and tie them down.
18. Disconnect the cooling fan electrical connector.
19. Remove the air intake duct.
20. Disconnect the return line from the power steering pump.
CAUTION: Be prepared to collect spilled liquid.
21. Remove the power steering high pressure line.
22.
Discard the seal. Plug all openings.
23. Disconnect the low pressure refrigerant line of the air conditioning (A/C) compressor.
Discard the seal. Plug all openings.
24. Remove the upper hose.
25. Disconnect the 2 fuel lines.
CAUTION: Be prepared to collect any spilled fuel.
26. Free the 2 fuel lines.
27. Disconnect the lower hose.
28. Remove the charge air cooler inlet pipe.
29. Disconnect the charge air cooler outlet hose.
30. Disconnect the engine wiring harness.
31. Left side: Release the 4 engine compartment ground cables.
32. Remove the expansion tank.
33. Disconnect the drive shaft from the gearbox drive flange.
34. Disconnect the 2 heater hoses from the bulkhead.
35. Disconnect the clutch fluid hose.
CAUTION: If brake fluid comes into contact with the paintwork, the affected area should be immediately washed with cold water.
36. Support the engine. General equipment: Powertrain Jack
37. Remove the left engine mount bracket.
38. Remove the left engine mount.
39. Right side: Release the engine mount.
40. With the help of a second mechanic, carefully remove the engine and gearbox.
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