Body System - Uni-Body, Subframe & Mounting System: Component Locations

Special Tool(s)

Illustration Name Number TKITNumber POWER TRAIN LIFT 300-OTC1585AE

Scheme 18

Scheme 18: Exploded View

Item	Service Part Number	Description	Torque
1	W714470	Front subframe forward bolt (2 required)	200 Nm (148 lb-ft)
2	5C145	Front subframe assembly
3	5L022	Front subframe forward bolt washer (2 required)
4	W714890	Lower ball joint nut (2 required)	200 Nm (148 lb-ft)
5	W520215	Outer tie-rod end nut (2 required)	150 Nm (111 lb-ft)
6	W505274	Stabilizer bar brackets-to-front subframe bolts (4 required)	55 Nm (41 lb-ft)
7	5G221	Front subframe bracket (2 required)
8	W710999	Front subframe bracket bolts (4 required)	55 Nm (41 lb-ft)
9	W714471	Front subframe rearward bolts (2 required)	200 Nm (148 lb-ft)

Illustration Name Number TKITNumber Remover/Installer, Front Subframe Bushing 204-362 TKIT-2005D1-F

Scheme 19

Scheme 19: Special Tool(s)

Scheme 20

Scheme 20: Removal

Remove the front subframe. REFER to «Subframe - Front»(ref-517624-S19700034142012121200000) .
Assemble the 204-362 to the front subframe.
Press out the subframe bushing.

Scheme 21

Scheme 21: Installation

Scheme 22

Assemble the 204-362 to the front subframe with the new subframe bushing.
Align the subframe bushing to the front subframe. Align the subframe bushing so that the voids are oriented in the fore-aft position.
Press the new subframe bushing into the front subframe.
Install the front subframe. REFER to «Subframe - Front»(ref-517624-S19700034142012121200000) .

Illustration Name Number TKITNumber Remover/Installer, Rear Drive Unit Bushing (60 Mm) 204-618 TKIT-2006UF-FLM Remover/Installer, Rear Drive Unit Bushing (70 Mm) 204-616 TKIT-2006UF-FLM

Scheme 23

Scheme 23: Special Tool(s)

Scheme 24

Scheme 25

Scheme 25: Exploded View

Item	Service Part Number	Description
1	4B425	RDU bushing - rear bushings (2 required)
2	5R003	Rear Subframe Assembly

Scheme 26

Scheme 26: Removal

NOTE: There are 2 RDU rear bushings in the rear subframe. This procedure shows how to remove one bushing. The procedure for the remaining RDU bushing is identical. Remove the RDU. REFER to «AXLE ASSEMBLY»(ref-517546-S16661696012012121200000) .
NOTE: The RDU 204-618 /1 must be used to remove the bushing to make sure that it passes through the receiver cup. NOTE: Make sure the RDU 204-616 /2 is positioned with the larger opening toward the bushing to act as the receiver cup. NOTE: Make sure the arrow on the RDU 204-616 is pointed toward the rear subframe when removing the bushing. Assemble the RDU 204-618 and the 204-616 to the rear subframe and press out the bushing.

Scheme 27

Scheme 27: Installation

Scheme 28

NOTE: There are 2 RDU rear bushings in the rear subframe. This procedure shows how to install one bushing. The procedure for the remaining RDU bushing is identical. NOTE: Make sure the alignment marks on the RDU 204-616 /2 are aligned with the anti-rotation tabs on the RDU bushing. Install the RDU bushing into the RDU 204-616 .
NOTE: Make sure the alignment marks are properly aligned on both the RDU 204-616 /1 and RDU 204-616 /2 and the anti-rotation tabs are properly seated in the RDU 204-616 . Install the RDU 204-616 onto the RDU bushing.
NOTE: Make sure the arrow on the RDU 204-616 /2 is visable on the bottom and is facing away from the subframe. The arrow must remain straight so the bushings are correctly indexed into the subframe. NOTE: When installing the RDU bushing, RDU 204-616 /2 will fall away as the RDU bushing is installed into the subframe. The RDU 204-616 does not control the depth of the bushing. The RDU bushing is fully seated when the RDU 204-616 /3 and RDU 204-616 /1 fall away from the subframe, do not continue to tighten the RDU 204-616 . Install the RDU bushing into the subframe.
Install the RDU. REFER to «AXLE ASSEMBLY»(ref-517546-S16661696012012121200000) .

Illustration Name Number TKITNumber Remover/Installer, Rear Drive Unit Bushing (60 Mm) 204-618 TKIT-2006UF-FLM Remover/Installer, Rear Drive Unit Bushing (70 Mm) 204-616 TKIT-2006UF-FLM

Scheme 29

Scheme 29: Special Tool(s)

Scheme 30

Scheme 30: Exploded View

Item	Service Part Number	Description
1	4B424	RDU bushing - front bushings (2 required)
2	5R003	Rear Subframe Assembly

Scheme 31

Scheme 31: Removal

NOTE: There are 2 RDU front bushings in the rear subframe. This procedure shows how to remove one bushing. The procedure for the remaining RDU bushing is identical. Remove the RDU. REFER to «AXLE ASSEMBLY»(ref-517546-S16661696012012121200000) .
NOTE: Make sure the RDU 204-618 /2 is positioned with the larger opening toward the bushing to act as the receiver cup. NOTE: Make sure the arrow on the RDU 204-616 /2 is pointed toward the rear subframe when removing the bushing. Assemble the RDU 204-618 and RDU 204-616 to the rear subframe and press out the bushing.

Scheme 32

Scheme 32: Installation

Scheme 33

Scheme 34

NOTE: There are 2 RDU front bushings in the rear subframe. This procedure shows how to install one bushing. The procedure for the remaining RDU bushing is identical. NOTE: Make sure the alignment marks on the RDU 204-616 /2 are aligned with the anti-rotation tabs on the RDU bushing. Install the RDU bushing into the RDU 204-616 /2.
NOTE: Make sure the alignment marks are properly aligned on both RDU 204-616 /1 and RDU 204-616 /2 and the anti-rotation tabs are properly seated in the RDU 204-616 . Install the RDU 204-616 /2 onto the RDU bushing.
NOTE: Make sure the arrow on the RDU 204-616 /2 is visible on the bottom and facing away from the subframe. The arrow must remain straight so that the bushings are correctly indexed into the subframe. NOTE: When installing the RDU bushing, RDU 204-618 /2 will fall away as the RDU bushing is installed into the subframe. The RDU 204-616 /2 does not control the depth of the bushing. The RDU bushing is fully seated when the RDU 204-616 /2 falls away from the subframe, do not continue to tighten the RDU 204-616 . Install the RDU bushing into the subframe.
Install the RDU. REFER to «AXLE ASSEMBLY»(ref-517546-S16661696012012121200000) .

Body System - Uni-Body, Subframe & Mounting System: Component Locations Ford Explorer V