Subframe: Service and Repair

Special Service Tool Required:

Removal

1. Mark hinge locations and remove hood (16612).
2. Disconnect battery ground cable (14301).
3. Remove engine air cleaner (ACL)(9600) and air cleaner outlet tube (9B659).
4. Remove cowl top vent panel (022A68), cowl top panel (02010) and cowl top inner panel tube (02206).

Three Bar Engine Support:

5. Install Rotunda Engine Lift Bracket Set 014-00792, Three Bar Engine Support 014-00750, and 3 Bar Adapter Set 014-00794 or equivalent on engine and transaxle assembly.
6. Raise vehicle on hoist.
7. Remove front wheel (1007) and tire assemblies.

Exhaust Connector Holder Tool:

8. Install Exhaust Connector Holder Tool T94T-6000-AH onto exhaust system flex tube (5G203).
9. Disconnect engine control sensor extension wiring (12A690) from heated oxygen sensors (HO2S)(9F472) on dual converter Y pipe (5F250).
10. Remove dual converter Y pipe.
11. Remove bolt clamping universal joint on steering column intermediate shaft coupling (3A525) to steering gear (3504).
12. Disconnect steering column intermediate shaft coupling from steering gear.
13. Disconnect power steering hoses from steering gear.
14. Remove wiring harness retainers from front sub-frame (SC145) and move engine control sensor extension wiring out of the way.
15. Remove nuts and disconnect front stabilizer bar links (5K483) from front stabilizer bar (5482).
16. Disconnect tie rod ends (3A130) from the right front wheel hub and spindle (3K206) and left front wheel hub and spindle.
17. Remove spindle-to-control arm pinch bolts and pry ball joint stud out of front wheel hub and spindle (3K207) on both sides.
18. Remove nuts retaining engine and transmission mounts to front sub-frame.
19. Support front sub-frame with Rotunda Hi-Lift Jack 014-00942 and Rotunda Sub-Frame Removal Kit 014-00751 or equivalent.

Front Sub-Frame:

20. Remove four sub-frame to body retaining bolts and lower body bolt absorbers (00155).

Front Sub-Frame:

21. Remove front sub-frame with attached:
- steering gear
- front stabilizer bar
- front suspension lower arm strut (3468)
- front suspension lower control arms
22. If necessary, remove the following from front sub-frame:
- steering gear
- front stabilizer bar
- front suspension lower arm strut
- front suspension lower control arms

Installation

1. If removed, install front suspension lower arms (3078) to front sub-frame. Tighten bolt to 133-153 N.m (98-113 lb-ft).
2. If removed, install front suspension lower arm struts. Tighten nuts to 115-132 N.m (85-97 lb-ft).
3. If removed, install front stabilizer bar on front sub-frame. Tighten bracket-to-sub-frame bolts to 55-63 N.m (40-46 lb-ft).
4. If removed, install steering gear on front sub-frame. Tighten bolts to 113-152 N-m (84-112 lb-ft).
5. Install front sub-frame with Rotunda Hi-Lift Jack 014-00942 and Rotunda Sub-Frame Removal Kit 014-00751 or equivalent. Guide studs on front engine support insulators (6038) and engine and transmission support insulator (6F063) into brackets.
6. Support front sub-frame in place with Rotunda Hi-Lift Jack 014-00210 or equivalent and Rotunda Sub-Frame Removal Kit 014-00751 or equivalent and install four sub-frame-to-body bolt absorbers. Tighten bolts to 77-103 N.m (57-75 lb-ft).
7. Tighten front engine support insulator nuts to 68-92 N.m (50-67 lb-ft).
8. Tighten nut on engine and transmission support insulator to 68-92 N.m (50-67 lb-ft).
9. Make sure stud on front suspension lower arm (3079) LH and front suspension lower arm RH. is straight up. Also make sure indentation on stud is facing toward center of vehicle. Pull down on front suspension lower arm , position front wheel hub and spindle and insert stud into front wheel hub and spindle.
10. Install pinch bolt into front wheel hub and spindle. Install nut and tighten to 54-71 N.m (40-53 lb-ft).
11. Install tie rod end to front wheel hub and spindle.
12. Install nut on tie rod end and tighten to 47-63 N.m (35-46 lb-ft). Advance nut so next slot in nut lines up with cotter pin hole in stud. Install cotter pin.
13. Install the front stabilizer bar link to front stabilizer bar. Tighten nuts to 90-100 N.m (67-73 lb-ft).
14. Repeat steps 9-13 on the other side of the vehicle.
15. Install wiring harness retainers into appropriate holes in front sub-frame.
16. Connect power steering hoses to steering gear.
17. Connect steering column intermediate shaft coupling to steering gear.
18. Install bolt clamping steering column input shaft coupling universal joint to steering gear. Tighten to 34-46 N.m (25-33 lb-ft).
19. Install dual converter Y pipe.
20. Connect engine control sensor extension wiring to heated oxygen sensors.
21. Remove Exhaust Connector Holder Tool T94T-6000-AH from exhaust system flex tube.
22. Install front wheel and tire assemblies.
23. Remove Rotunda Engine Lift Bracket Set 014-00792, Three Bar Engine Support 014-00750, and 3 Bar Adapter Kit 014-00794 or equivalent from engine and transaxle assembly.
24. Install cowl top inner panel tube, cowl top panel and cowl top vent panel.
25. Install engine air cleaner and air cleaner outlet tube.
26. Install and adjust hood.
27. Connect battery ground cable.
28. Perform front wheel alignment.
29. Fill and bleed power steering system with Premium Power Steering Fluid E6AZ-19582-AA or equivalent meeting Ford specification ESW-M2C33-F.