Engine Removal - 6-cyl & v6 Ford Thunderbird IX

2.4L (149") Diesel

1. Disconnect battery cables. Disconnect hood wiring assembly. Scribe hinge mark locations and remove hood. Drain crankcase and radiator. Remove intake manifold air cleaner assembly.
2. Remove fan shroud. Remove engine cooling fan assembly. Remove upper and lower radiator hoses. Disconnect transmission oil cooler lines. Remove radiator.
3. Discharge A/C system. When system is discharged, disconnect high and low pressure hoses. Cap hose openings to prevent entrance of dirt and excessive moisture.
4. Disconnect muffler inlet pipe. Disconnect vacuum hoses and wiring harnesses. Disconnect engine oil cooler hoses. Disconnect accelerator cable at fuel injection pump. Disconnect fuel line from tank to fuel injection pump.
5. Disconnect transmission gear shaft linkage. Remove coolant expansion bottle and position out of way. Disconnect heater hoses at dash panel. Disconnect wire to A/C compressor clutch. Disconnect power steering pump hoses. Disconnect wiring harnesses and grounds.
6. Install engine support tool. Raise vehicle on hoist. Remove muffler inlet pipe. Remove lower engine oil cooler bracket and brace. Remove stabilizer bar, bracket retaining bolts and position forward. Remove left front fender splash shield.
7. Disconnect steering gear input shaft-to-steering column shaft coupling. Remove retainer nuts-to-engine insulator supports. Position jack under engine. Raise engine. Position steering gear out of way. Lower engine.
8. Remove converter housing access cover. Remove converter retainer nuts. Insert pair of locking pliers in converter housing to hold converter in place during engine removal.
9. Remove No. 3 crossmember retainer nuts. Remove transmission gear shift lever bellcrank. Raise transmission. Remove No. 3 crossmember retainer bolts. Lower transmission. Remove engine-to-transmission converter housing retainer bolts.
10. Install No. 3 crossmember retainer bolts. Position jack and drain pan out of way. Lower vehicle. Install engine lifting equipment. Remove engine support tool. Remove engine.

3.8L (232")

1. Drain cooling system. Disconnect negative battery cable. If equipped with under-hood light, disconnect wiring connector. Mark hinges for reinstallation and remove hood.
2. Remove air cleaner assembly, air intake duct and heat tube. Remove fan shroud attaching screws. Remove fan/clutch assembly and shroud. Loosen accessory drive belt idler. Remove drive belt. Remove water pump pulley.
3. Disconnect upper and lower radiator hoses at radiator. Disconnect thermactor hose from downstream air tube check valve. Remove downstream air tube bracket bolt from rear of right cylinder head.
4. Remove coil secondary wire from coil. If equipped, remove power steering pump attaching bolts. Place pump aside with hoses connected.
5. If equipped, remove A/C compressor attaching bolts. Position compressor aside leaving refrigerant lines connected. Remove alternator. Disconnect heater hoses from heater tube and water pump.
6. If equipped, remove cruise control servo and bracket. Disconnect all vacuum hoses, electrical wiring and linkages from engine. Disconnect engine ground strap at dash panel. Disconnect transmission linkage at fuel charging assembly.
7. Disconnect flexible fuel hoses from steel lines over the rocker arm cover. Plug the hoses to prevent leakage. Remove CFI throttle body. Install engine lifting plate (T75T-6000-A or equivalent) over throttle body mounting studs. Tighten nuts securely. CAUTION: As intake manifold is die-cast aluminum and of light weight design, all studs must be used to secure lifting plate. When using lifting plate, do not remove engine with transmission attached.
8. Raise vehicle. Drain crankcase. Remove dust shield from converter housing. Remove flex plate-to-torque converter bolts. Disconnect battery cable from starter motor. Remove starter motor.
9. Remove transmission oil cooler line routing clip. Remove exhaust inlet pipe at exhaust manifold. If equipped, disconnect exhaust heat control valve vacuum line. Remove valve from exhaust manifold studs.
10. Remove transmission-to-engine lower attaching bolts. Remove engine mount-to-crossmember bolts. Lower vehicle. Support transmission with a jack.
11. Remove upper transmission-to-engine attaching bolts. Slightly raise engine. Carefully pull engine away from transmission. Remove engine from engine compartment.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS