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Body System - Uni-Body, Subframe & Mounting System: Removal & Installation Ford Flex I

Frames, Subframes & Crossmembers 24 illustrations ~1896 words

Removal

All vehicles

Scheme 1

Scheme 1: Removal
Scheme 1: Removal

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Scheme 2
Scheme 2

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Scheme 3

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Scheme 5

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Scheme 7

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Scheme 9

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Scheme 14
Scheme 14
  1. Remove the wheels and tires. For additional information, Refer to «WHEELS AND TIRES»(ref-372756) . Vehicles equipped with Electronic Power Assist Steering (EPAS)
  2. NOTE: Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent). Using a suitable holding device, hold the steering wheel in the straight-ahead position.
  3. Remove the 4 retainers and the underbody shield. All vehicles
  4. Remove the 2 RH lower pin-type retainers from the engine splash shield and position the shield aside. Vehicles equipped with EPAS
  5. Remove the RH and LH exhaust flexible pipes. For additional information, Refer to «EXHAUST SYSTEM»(ref-372760) . Vehicles equipped with Hydraulic Power Assist Steering (HPAS)
  6. Remove the engine exhaust Y-pipe. For additional information, Refer to «EXHAUST SYSTEM»(ref-372760) .
  7. Remove and discard the stabilizer bar bracket-to-front subframe bolts. Vehicles equipped with EPAS
  8. NOTE: RH shown in illustration, LH similar. Remove and discard the upper stabilizer link nuts. All vehicles
  9. NOTE: The hex-holding feature can be used to prevent turning of the stud while removing the nut. NOTE: RH shown in illustration, LH similar. Remove and discard the tie-rod end nuts. Separate the tie-rod ends from the wheel knuckles.
  10. NOTE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part number or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. NOTE: Use care when releasing the lower arm and knuckle into the resting position or damage to the ball joint seal or Constant Velocity (CV) boot may occur. NOTE: Use the hex-holding feature to prevent the stud from turning while removing the nut. NOTE: RH shown in illustration, LH similar. Remove and discard the lower ball joint-to-wheel knuckle nuts. Separate the lower ball joints from the wheel knuckles. Vehicles equipped with HPAS
  11. Remove the 2 power steering line routing bolts.
  12. Remove the power steering gear-to-front subframe bolts and nuts.
  13. Support the power steering gear and stabilizer bar to the underbody of the vehicle with mechanic's wire. Vehicles equipped with EPAS
  14. Remove the bolt and disconnect the 2 Electronic Power Assist Steering (EPAS) electrical connectors (1 shown in illustration) and the wiring retainer (not shown in illustration).
  15. NOTE: Do not allow the steering column to rotate while the steering column shaft is disconnected from the steering gear or damage to the clockspring may occur. If there is evidence that the steering column has rotated, the clockspring must be removed and recentered. For additional information, Refer to «SUPPLEMENTAL RESTRAINT SYSTEM»(ref-372796) . Remove the bolt and disconnect the steering column shaft from the steering gear. Discard the bolt. All vehicles
  16. Remove the rear engine roll restrictor bolt.
  17. Remove the front engine roll restrictor bolt.
  18. Position the Powertrain Lift Table under the subframe assembly.
  19. NOTE: RH shown in illustration, LH similar. Remove and discard the subframe bracket-to-body bolts.
  20. NOTE: RH shown in illustration, LH similar. Remove and discard the rear subframe bolts and remove the subframe brackets.
  21. NOTE: RH shown in illustration, LH similar. Remove and discard the front subframe bolts.
  22. Lower the subframe assembly from the vehicle.

Installation

All vehicles

Scheme 15

Scheme 15
Scheme 15

Scheme 16

Scheme 16
Scheme 16
  1. Using the Powertrain Lift Table, raise the subframe into the installed position.
  2. NOTE: RH shown in illustration, LH similar. Install the 2 new front subframe bolts. Tighten to 200 Nm (148 lb-ft).
  3. NOTE: RH shown in illustration, LH similar. Position the subframe brackets and install the 4 new bolts finger-tight.
  4. NOTE: RH shown in illustration, LH similar. Install the 2 new rear subframe bolts. Tighten to 150 Nm (111 lb-ft).
  5. NOTE: RH shown in illustration, LH similar. Tighten the 4 new subframe bracket-to-body bolts to 55 Nm (41 lb-ft).
  6. Install the front engine roll restrictor bolt. Tighten to 90 Nm (66 lb-ft).
  7. Install the rear engine roll restrictor bolt. Tighten to 90 Nm (66 lb-ft). Vehicles equipped with EPAS
  8. NOTE: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring may occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. For additional information, Refer to «SUPPLEMENTAL RESTRAINT SYSTEM»(ref-372796) . Install the steering intermediate shaft onto the steering gear and install a new bolt. Tighten to 20 Nm (177 lb-in).
  9. Connect the 2 EPAS electrical connectors (1 shown in illustration) and attach the wiring retainer (not shown in illustration) and install the bolt. Tighten to 9 Nm (80 lb-in). All vehicles
  10. NOTE: RH shown in illustration, LH similar. Position the ball joints into the wheel knuckles. Install the new ball joint nuts. Tighten to 200 Nm (148 lb-ft).
  11. NOTE: The hex-holding feature can be used to prevent turning of the stud while installing the nuts. NOTE: RH shown in illustration, LH similar. Install new tie-rod end nuts. Tighten to 150 Nm (111 lb-ft).
  12. NOTE: RH shown in illustration, LH similar. Install new upper stabilizer bar link nuts. Tighten to 150 Nm (111 lb-ft). Vehicles equipped with HPAS
  13. Remove the power steering gear support from the underbody of the vehicle.
  14. Install the power steering gear-to-front subframe bolts and nuts. Tighten to 117 Nm (86 lb-ft).
  15. Install the power steering line bolts. Tighten to 7 Nm (62 lb-in).
  16. Install the new stabilizer bar bracket-to-front subframe bolts. Tighten to 50 Nm (37 lb-ft).
  17. Install the engine exhaust Y-pipe. For additional information, Refer to «EXHAUST SYSTEM»(ref-372760) . Vehicles equipped with EPAS
  18. Install the RH and LH exhaust flexible pipes. For additional information, Refer to «EXHAUST SYSTEM»(ref-372760) . All vehicles
  19. Position the RH engine splash shield and install the 2 lower pin-type retainers. Vehicles equipped with EPAS
  20. Install the underbody shield and the 4 retainers. All vehicles
  21. Install the wheels and tires. For additional information, Refer to «WHEELS AND TIRES»(ref-372756) .
  22. Check the front end alignment and adjust as necessary. For additional information, Refer to «SUSPENSION SYSTEM - GENERAL INFORMATION»(ref-372757) .

Note. There are 2 Rear Drive Unit (RDU) rear bushings in the rear subframe. This procedure shows how to remove one bushing. The procedure for the remaining RDU bushing is identical.

Scheme 17

Scheme 17: Removal
Scheme 17: Removal
  1. Remove the RDU. For additional information, Refer to «REAR DRIVE AXLE/DIFFERENTIAL»(ref-372780) .
  2. NOTE: The Rear Drive Unit (RDU) Bushing (65 mm) Remover/Installer 204-618/1 must be used to remove the bushing to make sure that it passes through the receiver cup. NOTE: Make sure the Rear Drive Unit (RDU) Bushing (70 mm) Remover/Installer 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 Rear Drive Unit (RDU) Bushing (70 mm) Remover/Installer is pointed toward the rear subframe when removing the bushing. Assemble the Rear Drive Unit (RDU) Bushing (65 mm) Remover/Installer and the Rear Drive Unit (RDU) Bushing (70 mm) Remover/Installer to the rear subframe and press out the bushing.

Note. There are 2 RDU rear bushings in the subframe. This procedure shows how to install one bushing. The procedure for the remaining RDU bushing is identical.

Scheme 18

Scheme 18: Installation
Scheme 18: Installation

Scheme 19

Scheme 19
Scheme 19

Scheme 20

Scheme 20
Scheme 20
  1. NOTE: Make sure the alignment marks on the Rear Drive Unit (RDU) Bushing (70 mm) Remover/Installer 204-616/2 are aligned with the anti-rotation tabs on the RDU bushing. Install the RDU bushing into the Rear Drive Unit (RDU) Bushing (70 mm) Remover/Installer 204-616/2.
  2. NOTE: Make sure the alignment marks are properly aligned on both the Rear Drive Unit (RDU) Bushing (70 mm) Remover/Installer 204-616/1 and Rear Drive Unit (RDU) Bushing (70 mm) Remover/Installer 204-616/2 and the anti-rotation tabs are properly seated in the Rear Drive Unit (RDU) Bushing (70 mm) Remover/Installer 204-616. Install the Rear Drive Unit (RDU) Bushing (70 mm) Remover/Installer 204-616 onto the RDU bushing.
  3. NOTE: Make sure the arrow on the Rear Drive Unit (RDU) Bushing (70 mm) Remover/Installer 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, Rear Drive Unit (RDU) Bushing (70 mm) Remover/Installer 204-616/2 will fall away as the RDU bushing is installed into the subframe. The Rear Drive Unit (RDU) Bushing (70 mm) Remover/Installer does not control the depth of the bushing. The RDU bushing is fully seated when the Rear Drive Unit (RDU) Bushing (70 mm) Remover/Installer 204-616/3 and Rear Drive Unit (RDU) Bushing (70 mm) Remover/Installer 204-616/1 fall away from the subframe, do not continue to tighten the Rear Drive Unit (RDU) Bushing (70 mm) Remover/Installer. Install the RDU bushing into the subframe.
  4. Install the RDU. For additional information, Refer to «REAR DRIVE AXLE/DIFFERENTIAL»(ref-372780) .

Note. There are 2 Rear Drive Unit (RDU) front bushings in the rear subframe. This procedure shows how to remove one bushing. The procedure for the remaining RDU bushing is identical.

  1. Remove the RDU . For additional information, Refer to «REAR DRIVE AXLE/DIFFERENTIAL»(ref-372780) .
  2. NOTE: Make sure the Rear Drive Unit (RDU) Bushing (65 mm) Remover/Installer 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 Rear Drive Unit (RDU) Bushing (70 mm) Remover/Installer 204-616/2 is pointed toward the rear subframe when removing the bushing.

Assemble the Rear Drive Unit (RDU) Bushing (65 mm) Remover/Installer 204-618 and Rear Drive Unit (RDU) Bushing (70 mm) Remover/Installer 204-616 to the rear subframe and press out the bushing.

Scheme 21

Scheme 21
Scheme 21

Note. There are 2 RDU front bushings in the subframe. This procedure shows how to install one bushing. The procedure for the remaining RDU bushing is identical.

Scheme 22

Scheme 22: Installation
Scheme 22: Installation

Scheme 23

Scheme 23
Scheme 23

Scheme 24

Scheme 24
Scheme 24
  1. NOTE: Make sure the alignment marks on the Rear Drive Unit (RDU) Bushing (70 mm) Remover/Installer 204-616/2 are aligned with the anti-rotation tabs on the RDU bushing. Install the RDU bushing into the Rear Drive Unit (RDU) Bushing (70 mm) Remover/Installer 204-616/2.
  2. NOTE: Make sure the alignment marks are properly aligned on both Rear Drive Unit (RDU) Bushing (70 mm) Remover/Installer 204-616/1 and Rear Drive Unit (RDU) Bushing (70 mm) Remover/Installer 204-616/2 and the anti-rotation tabs are properly seated in the Rear Drive Unit (RDU) Bushing (70 mm) Remover/Installer 204-616. Install the Rear Drive Unit (RDU) Bushing (70 mm) Remover/Installer 204-616/2 onto the RDU bushing.
  3. NOTE: Make sure the arrow on the Rear Drive Unit (RDU) Bushing (70 mm) Remover/Installer 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, Rear Drive Unit (RDU) Bushing (65 mm) Remover/Installer 204-618/2 will fall away as the RDU bushing is installed into the subframe. The Rear Drive Unit (RDU) Bushing (70 mm) Remover/Installer does not control the depth of the bushing. The RDU bushing is fully seated when the Rear Drive Unit (RDU) Bushing (70 mm) Remover/Installer falls away from the subframe, do not continue to tighten the Rear Drive Unit (RDU) Bushing (70 mm) Remover/Installer. Install the RDU bushing into the subframe.
  4. Install the RDU. For additional information, Refer to «REAR DRIVE AXLE/DIFFERENTIAL»(ref-372780) .

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