Engine - 3.0L V6: Removal & Installation Ford Windstar I

REMOVAL & INSTALLATION

Note. For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Place mating marks on engine hood and other major assemblies before removal.

Removal (Ranger)

1. Disconnect negative battery cable and drain cooling system. Remove hood, air cleaner and intake duct assembly. Disconnect upper and lower radiator hose at radiator. Remove left-hand thread nut retaining fan clutch using Fan Clutch Holder (T84T-6312-C) and Fan Clutch Nut Wrench (T84T-6312-D). Remove cooling fan assembly. Remove accessory drive belt.
2. Disconnect transmission cooling lines from radiator (if equipped). Remove radiator and shroud. Discharge A/C system using approved refrigerant recovery/recycling equipment. Disconnect A/C liquid line at condenser and suction line from accumulator, and plug openings. Remove A/C hose assembly bracket from A/C compressor. Remove A/C hose assembly from vehicle.
3. Plug all openings in A/C system to prevent contamination. Remove A/C compressor bracket with A/C compressor and power steering pump attached, and position aside. Disconnect heater hoses from engine. Remove dash panel ground cables from engine. Release fuel pressure. See «FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS»(ref-1331-S20183414982000031300000). Using Spring Lock Coupling Remover (D87L-9280-A for 3/8" line or D87L-9280-B for 1/2" line), disconnect fuel supply and return lines. see scheme 1
4. Disconnect and remove EGR tube. Disconnect throttle cable linkage and shield at throttle body and intake manifold. Disconnect cruise control cable (if equipped). Mark location and disconnect all vacuum hoses from rear vacuum fitting in upper intake manifold.
5. Disconnect engine control wire harness from Power Train Control Module (PCM). Set No. 1 cylinder at TDC of compression stroke. Note position of camshaft position sensor electrical connector and remove connector. Remove camshaft position sensor retaining screws and remove sensor. On M/T models, place transmission in fourth gear. On A/T models, place transmission in Park. On all models, raise and support vehicle.
6. Remove transmission oil cooler line bracket from right side of engine. Disconnect exhaust pipes from manifolds. Remove starter and front engine mount nuts or through-bolts. Remove ground wires from engine block.
7. On A/T models, remove torque converter inspection cover. Remove flexplate-to-torque converter bolts. Remove kickdown cable and bellhousing mounting bolts. On M/T models, remove bellhousing bolts. On all models, remove engine front support-to-crossmember nuts and bolts.
8. Partially lower vehicle and attach engine hoist to brackets at exhaust manifolds. Ensure all wires and hoses are disconnected before raising engine. Support transmission. Raise engine slightly and carefully pull engine forward from transmission without damaging rear cover plate. Remove engine from vehicle.

Installation (Ranger)

To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS table. Check and fill all fluid levels. Start engine and check for leaks. Check front end alignment and adjust as necessary.

Removal (Windstar)

1. Disconnect negative battery cable. Drain cooling system. Discharge A/C system using approved refrigerant recovery/recycling equipment. Remove top cowl vent panel. Disconnect alternator wiring connections. Remove air cleaner and intake duct assembly. Disconnect upper radiator hose at radiator. Disconnect heater hoses. Disconnect A/C compressor hoses from receiver-drier and condenser. Plug openings.
2. Disconnect control cables from throttle body. Remove accelerator cable bracket from throttle body, and position aside. Release fuel pressure. Disconnect fuel supply and return lines. See «FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS»(ref-1331-S20183414982000031300000) .
3. Disconnect engine control wire harness from Powertrain Control Module (PCM). Disconnect other wire harness connectors and ground wires as necessary. Disconnect necessary vacuum and water hoses. Remove transmission shifter cable. CAUTION: Damage to steering column air bag wiring can result if steering wheel is allowed to rotate too far in either direction.
4. Lock steering wheel with wheels in straight-ahead position. Raise and secure vehicle. Remove front wheel assemblies. Drain engine oil. Disconnect transmission cooler lines from transmission. NOTE: Do not let flex connector of dual-converter "Y" pipe to hang unsupported.
5. Remove dual-converter "Y" pipe. Disconnect starter motor wiring and remove starter. Remove torque converter-to-flywheel nuts. Remove battery cable support. Disconnect power steering cooler hoses and lower radiator hose. Remove auxiliary heater hoses (if equipped).
6. Remove upper sway bar link bolts. Separate steering knuckles from front struts. Remove steering coupling pinch bolt from intermediate shaft. Remove intermediate shaft from steering gear. Remove both axle shafts. See «FWD AXLE SHAFTS - VILLAGER & WINDSTAR»(ref-91) article in DRIVE AXLES.
7. Support subframe, engine and transaxle assembly with Rotunda Powertrain Lift (014-00765) and Adapter (014-00341). Remove 4 front subframe retaining bolts. Partially lower engine, transaxle and subframe from vehicle as an assembly. Disconnect power steering hoses. Disconnect remaining electrical connections. Remove assembly from vehicle and disassemble as necessary.

Installation (Windstar)

To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Check and fill all fluid levels. Start engine and check for leaks. Check front end alignment and adjust as necessary.

Removal (Upper)

1. Disconnect negative battery cable. Release fuel pressure. See «FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS»(ref-1331-S20183414982000031300000) . On Windstar, remove top cowl vent panel. On all models, remove air cleaner duct hose. Mark and disconnect electrical connectors. Mark and disconnect vacuum hoses. Disconnect PCV hose. Remove throttle linkage shield and disconnect accelerator cable from throttle body. Remove accelerator cable bracket, and position aside.
2. Remove throttle body and throttle body gasket if necessary. Disconnect spark plug wires from ignition coil, and position aside. Remove ignition coil assembly. Remove EGR tube. Remove 6 upper intake manifold assembly bolts. Remove upper intake manifold and throttle body as assembly. Remove intake manifold gasket.

Installation (Upper)

Clean gasket mating surfaces using caution not to gouge plastic or aluminum parts. Install a NEW gasket. Use guide pins and install upper intake manifold. Tighten bolts in sequence to specification. (Scheme 2) See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure.

Scheme 2

Removal (Lower)

1. Disconnect negative battery cable. Drain cooling system. Remove air cleaner duct hose. Relieve fuel pressure. See «FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS»(ref-1331-S20183414982000031300000). Using Spring Lock Coupling Remover (D87L-9280-A) for 3/8" line or (D87L-9280-A) for 1/2" line, disconnect fuel supply and return lines. see scheme 1
2. Remove throttle linkage shield and disconnect linkage. Mark and disconnect vacuum hoses from throttle body. Mark and disconnect electrical connectors. Disconnect upper radiator hose from thermostat housing. Remove ignition coil from throttle body.
3. Remove upper intake manifold. Remove generator support brace. Disconnect fuel injector harness connectors. Remove fuel injector supply manifold and injectors as assembly. Disconnect heater hoses. Remove spark plug wires. Rotate engine until No. 1 piston is at TDC on compression stroke.
4. Note position of camshaft position sensor electrical connector on sensor and remove connector. Remove camshaft position sensor retaining screws and remove sensor. Remove valve covers. See «VALVE COVER»(ref-1331-S24911843512000031300000). Note locations of rocker arms and push rods and remove rocker arms and push rods. Loosen cylinder No. 3 intake valve rocker arm. Rotate rocker arm off push rod. Remove push rod. Remove intake manifold retaining bolts. Remove generator if necessary. Remove lower intake manifold.

Installation (Lower)

1. Lightly oil all retaining bolts and stud threads before installation. Apply silicone sealer to 4 intersecting corners of cylinder block and cylinder head. Install front and rear intake manifold seals. Position lower intake manifold gaskets in place with locking tabs over tabs on cylinder head gaskets.
2. Carefully install lower intake manifold. Install manifold retaining bolts and tighten in sequence to specification. (Scheme 3) See «TORQUE SPECIFICATIONS»(ref-1331-S42351287512000031300000) table.
3. Install push rods and rocker arms in original locations. Tighten rocker arm bolts to specification. See «TORQUE SPECIFICATIONS»(ref-1331-S15552572152000031300000). To complete installation, reverse removal procedure.

Scheme 3

Disconnect negative battery cable. If removing right exhaust manifold, remove spark plugs. If removing left exhaust manifold, remove EGR tube and oil dipstick tube. Separate exhaust pipes from exhaust manifolds. Note location of studs and bolts for reinstallation. Remove exhaust manifold studs and bolts. Remove exhaust manifolds.

Disconnect negative battery cable. If removing left exhaust manifold, remove oil dipstick tube. If removing right exhaust manifold, remove EGR tube and cowl top vent panel. Separate exhaust pipes from exhaust manifolds. Note location of studs and bolts for reinstallation. Remove exhaust manifold studs and bolts. Remove exhaust manifolds.

Installation (All Models)

Clean carbon from mating surfaces. Lightly oil threads of bolts and stud before installation. Install exhaust manifold(s) and tighten bolts in sequence to specification. (Scheme 4) See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure.

Scheme 4

1. Disconnect negative battery cable. Remove fresh air hose from air cleaner. Mark spark plug wires and remove from spark plugs. Remove spark plug wire separators from valve cover studs. For left valve cover, remove upper intake manifold. See «INTAKE MANIFOLD»(ref-1331-S14055921652000031300000) .
2. Remove PCV valve. Disconnect injector wiring harness bracket from left valve cover studs. Disconnect engine wiring harness connectors from right valve cover.
3. Disconnect injector wiring harness bracket from right valve cover studs. Disconnect breather hose. Remove valve cover retaining bolts and studs.
4. Carefully slide a thin knife between cylinder head and valve cover. Cut silicone sealer. Avoid cutting integral gasket. Remove valve cover(s).

1. Disconnect negative battery cable. Remove top cowl vent panel. Mark spark plug wires and remove from spark plugs. Remove spark plug wire separators from valve cover studs. For right valve cover, remove upper intake manifold and EGR manifold tube. See «INTAKE MANIFOLD»(ref-1331-S14055921652000031300000) .
2. Remove PCV valve. Disconnect injector wiring harness bracket from left valve cover studs. For left valve cover, remove oil filler tube. Disconnect engine wiring harness connectors from left valve cover. Disconnect injector wiring harness bracket from left valve cover studs. Disconnect breather hose. Remove valve cover retaining bolts and studs.
3. Carefully slide a thin-blade tool between cylinder head and valve cover. Cut silicone sealer; avoid cutting integral gasket. Remove valve cover(s).

1. If replacing gasket, note position of studs and bolts before removing. Replace valve cover gasket if necessary. Ensure gasket lies flat in valve cover channel. Lightly oil threads of bolts and studs. Ensure sealing surfaces are clean.
2. Apply a bead of silicone sealant to intake manifold-to-cylinder head joining area. Install valve cover and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-1331-S15552572152000031300000) . To complete installation, reverse removal procedure.

1. Remove upper and lower intake manifolds. See «INTAKE MANIFOLD»(ref-1331-S14055921652000031300000) . Discharge A/C system using approved refrigerant recovery/recycling equipment. Disconnect liquid line at condenser and suction line from accumulator. Remove hose assembly bracket from A/C compressor and remove A/C hose assembly from vehicle. Plug all openings in A/C system to prevent contamination.
2. Remove accessory drive belt. When removing left cylinder head, remove power steering pump bracket retaining bolts. Remove power steering pump and bracket as an assembly (with hoses attached), and position aside.
3. Remove dipstick tube retaining nut from exhaust manifold. Rotate or remove dipstick tube. When removing right cylinder head, remove generator bracket and adjusting arm as an assembly. Remove fuel line bracket from cylinder head.
4. Remove exhaust manifolds. See «EXHAUST MANIFOLD»(ref-1331-S01615134202000031300000) . Remove valve covers. See «VALVE COVER»(ref-1331-S24911843512000031300000) . Loosen rocker arm bolts and move rocker arms off push rods. Remove push rods and label push rods for installation reference. Remove and discard cylinder head bolts. Remove cylinder head and gasket.

1. Rotate crankshaft so No.1 piston is at TDC of compression stroke. Disconnect negative battery cable. Drain cooling system. Remove top cowl vent panel. Remove upper and lower intake manifolds. See «INTAKE MANIFOLD»(ref-1331-S14055921652000031300000) . Disconnect necessary wiring connectors and vacuum hoses.
2. Remove drive belts and tensioners. Remove valve covers. See «VALVE COVER»(ref-1331-S24911843512000031300000) . Remove ignition coil assembly. Disconnect upper radiator and heater hoses. Remove exhaust manifolds. See «EXHAUST MANIFOLD»(ref-1331-S01615134202000031300000) . Loosen rocker arms and rotate them to one side. Remove push rods, label push rods for installation.
3. If removing left cylinder head, remove generator, oil dipstick tube and power steering pump and bracket. If removing right cylinder head, remove heater supply tube and vehicle speed sensor. Remove cylinder head bolts and cylinder head.

1. Replace locating dowels in cylinder block if damaged. Position NEW head gasket over locating dowels on cylinder block, with marked side in proper position. NOTE: "V" notch below TRUCK marking on gasket indicates right side head gasket. "V" notch above TRUCK marking on gasket indicates left side head gasket. (Scheme 5) Ensure UP mark on gasket faces upward.
2. Install cylinder head and NEW cylinder head bolts. Tighten cylinder head bolts in sequence to specification. (Scheme 5) See «TORQUE SPECIFICATIONS»(ref-1331-S42351287512000031300000) table. Dip each push rod end in Oil Conditioner (D9AZ-19579-D). Install push rods in their original location.
3. For each valve, rotate crankshaft until lifter rests on base circle of camshaft lobe. Position rocker arm over push rod and install fulcrum. Tighten rocker arm bolts to specification in 2 steps. See «TORQUE SPECIFICATIONS»(ref-1331-S15552572152000031300000). NOTE: Rocker arms must be fully seated in cylinder head and push rods must be seated in rocker arm sockets before final tightening. Camshaft may be in any position before final tightening. If all original components removed are reinstalled, valve clearance check is not required. If valves/seats were serviced, check and adjust valve clearance. See «VALVE CLEARANCE ADJUSTMENT»(ref-1331-S35354647902000031300000) under ADJUSTMENTS.
4. To complete installation, reverse removal procedure. Tighten all bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-1331-S15552572152000031300000). Fill and bleed cooling system.

Scheme 5

Removal

Disconnect negative battery cable. Remove air cleaner duct hose. Remove accessory drive belt. Remove crankshaft pulley. Remove crankshaft damper using Crankshaft Damper Remover and Adapter (T58P-6316-D and T82L-6316-B). Pry seal out carefully to avoid damaging sealing surface.

Installation

Lubricate lip of seal with clean engine oil. Using a proper size seal installer, install seal. Lubricate damper seal surface with engine oil. Apply RTV sealer to damper keyway. To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

1. Remove negative battery cable. Drain cooling system. Remove accessory drive belt. Remove left-hand thread nut retaining clutch fan to pulley. Remove cooling fan and water pump pulley. Remove A/C bracket, brace and compressor as an assembly (if equipped), and position aside. Remove generator adjusting arm and brace, and position generator aside.
2. Remove crankshaft pulley. Using Crankshaft Damper Remover and Adapter (T58P-6316-D and T82L-6316-B), remove crankshaft damper. Remove hoses from water pump.
3. Remove oil pan. See «OIL PAN»(ref-1331-S09702226492000031300000). Remove bolts retaining timing chain cover and water pump assembly to engine. (Scheme 6) Remove timing chain cover and water pump as an assembly.

1. Remove negative battery cable. Drain cooling system. Loosen water pump pulley with drive belt in place. Remove accessory drive belt and water pump pulley. Remove drive belt tensioner. Raise and support vehicle. Remove right front wheel assembly and lower radiator hose.
2. Remove crankshaft pulley. Using Crankshaft Damper Remover and Adapter (T58P-6316-D and T82L-6316-B), remove crankshaft damper. Remove hoses from water pump. Remove oil pan. See «OIL PAN»(ref-1331-S09702226492000031300000). Remove bolts retaining timing chain cover and water pump assembly to engine. (Scheme 6) Remove timing chain cover and water pump as an assembly.

1. Clean all gasket mating surfaces. Coat both surfaces of NEW timing chain cover gasket with sealing compound. Install timing chain cover gasket. Install timing chain cover. Lightly oil threads of bolt and stud, except those with Teflon sealant, before installation. (Scheme 6)
2. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-1331-S15552572152000031300000). To complete installation, reverse removal procedure. Fill and bleed cooling system.

Scheme 6

Disconnect negative battery cable. Remove timing chain cover. See TIMING CHAIN COVER. Position No. 1 piston on TDC of compression stroke. (Scheme 7) Check alignment of camshaft and crankshaft sprocket timing marks. Check timing chain deflection. See INSPECTION. Remove camshaft sprocket retaining bolt and washer. Slide sprockets and timing chain forward and remove as an assembly.

1. Ensure No. 1 piston is still at TDC of compression stroke. Assemble timing chain and sprockets so sprocket timing marks are aligned. (Scheme 7) Install chain and sprockets as an assembly. Lubricate timing chain and sprockets with engine oil.
2. Apply RTV sealer to damper keyway. To complete installation, reverse removal procedure. Tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-1331-S15552572152000031300000).

Scheme 7

1. Disconnect negative battery cable. Drain cooling system and remove radiator. Discharge A/C system using approved refrigerant recovery/recycling equipment. Remove A/C condenser (if equipped). Plug A/C lines. Remove timing chain and sprockets. See «TIMING CHAIN & SPROCKETS»(ref-1331-S08130031962000031300000) . Remove intake manifold. See «INTAKE MANIFOLD»(ref-1331-S14055921652000031300000) . Remove valve covers. See «VALVE COVER»(ref-1331-S24911843512000031300000) .
2. Loosen rocker arm bolts and rotate rocker arms off push rods. Remove push rods and keep push rods in order for installation reference. Remove lifter guide plate retainer. Remove lifter guide plates from lifters.
3. Remove lifters, keeping them in order. Check camshaft end play. If end play is not within specification, replace thrust plate and inspect camshaft. See «CAMSHAFT»(ref-1331-S33766745892000031300000) table under ENGINE SPECIFICATIONS. Remove camshaft thrust plate. Slowly pull camshaft from engine, keeping camshaft in line with camshaft bores.

1. Lubricate camshaft lobes and journals with heavy SAE 50W engine oil. Carefully slide camshaft through bearings in cylinder block. Install thrust plate and recheck camshaft end play. Install timing chain and sprocket as an assembly.
2. Ensure crankshaft and camshaft sprockets are aligned. (Scheme 7) Install camshaft sprocket washer and retaining bolt, and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-1331-S15552572152000031300000). Lubricate valve lifters and bores with SAE 50W engine oil.
3. Install lifters in their original bores. Lubricate push rods with SAE 50W engine oil. Install push rods in their original location. For each valve, rotate crankshaft until lifter rests on heel of camshaft lobe. Position rocker arm over push rod and install fulcrum.
4. Tighten rocker arm bolts in 2 steps to specification. See «TORQUE SPECIFICATIONS»(ref-1331-S15552572152000031300000). To complete installation, reverse removal procedure.
5. Install camshaft position sensor synchronizer. For installation and alignment procedure, see: 1998 Ranger «REMOVE/INSTALL/OVERHAUL - 3.0L»(ref-131337) article in ENGINE PERFORMANCE 1999 Ranger «REMOVAL, OVERHAUL & INSTALLATION»(ref-2285) article in ENGINE PERFORMANCE 2000 Ranger «REMOVAL, OVERHAUL & INSTALLATION»(ref-2871) article in ENGINE PERFORMANCE 1998 Windstar «REMOVE/INSTALL/OVERHAUL - 3.0L»(ref-131341) article in ENGINE PERFORMANCE 1999 Windstar «REMOVAL, OVERHAUL & INSTALLATION»(ref-2285) article in ENGINE PERFORMANCE
6. Tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-1331-S15552572152000031300000). Fill or top off all fluids. Fill cooling system. Start engine and check for leaks. Check and adjust ignition timing as necessary.

Remove transmission. For 1998-99 models with A/T, see TRANSMISSION REMOVAL & INSTALLATION - TRUCKS article in TRANSMISSION SERVICING. For 2000 models with A/T, see TRANSMISSION REMOVAL & INSTALLATION - LIGHT TRUCKS & VANS article in TRANSMISSION SERVICING. Remove clutch assembly (if equipped). For 1998-99 models, see EXPLORER & RANGER article in CLUTCHES. For 2000 models, see EXPLORER, EXPLORER SPORT, EXPLORER SPORT TRAC & RANGER article in CLUTCHES. Remove flywheel/flexplate. Using a slide hammer, remove rear oil seal. DO NOT damage crankshaft sealing surface. Coat seal surfaces with heavy SF engine oil. Using Rear Main Seal Installer (T88L-6701-A), install seal until firmly seated. To complete installation, reverse removal procedure.

1. Disconnect negative battery cable. Remove air cleaner duct. Drain cooling system. Using Fan Clutch Holder (T96T-6312-B) and Fan Clutch Wrench (T96T-6312-A), remove nut retaining clutch fan to pulley. Remove fan shroud and cooling fan as an assembly.
2. Loosen water pump pulley retaining screws. Rotate drive belt tensioner clockwise and remove accessory drive belt. Remove water pump pulley. Remove by-pass hose from intake manifold. Remove A/C compressor and bracket as an assembly, and support with wire.
3. Remove lower radiator and heater hose from water pump. Remove 12 water pump bolts. Remove water pump.

Disconnect negative battery cable. Drain cooling system. Loosen water pump pulley bolts with drive belt still tight. Remove drive belt and driver belt tensioner. Disconnect lower radiator and heater hoses at water pump. Remove 11 water pump bolts and remove water pump.

Clean all gasket surfaces. Lightly oil threads of bolt and stud, except those with Teflon sealant, before installation. (Scheme 6) Use sealant on bolts going into water jacket. Apply contact adhesive to NEW gasket and position on water pump. Install water pump. To complete installation, reverse removal procedure. Fill cooling system and check for leaks.

Removal (Ranger 2WD)

1. Remove the air cleaner outlet tube. See «AIR CLEANER OUTLET TUBE»(ref-1331-S09558084122002120600000).
2. Remove the transmission. For 1998-99 models with A/T, see «TRANSMISSION REMOVAL & INSTALLATION - TRUCKS»(ref-1146) article in TRANSMISSION SERVICING. For 2000 models with A/T, see «TRANSMISSION REMOVAL & INSTALLATION - LIGHT TRUCKS & VANS»(ref-97206) article in TRANSMISSION SERVICING. Remove clutch assembly (if equipped). For 1998-99 models, see «EXPLORER & RANGER»(ref-1367) article in CLUTCHES. For 2000 models, see «EXPLORER, EXPLORER SPORT, EXPLORER SPORT TRAC & RANGER»(ref-94680) article in CLUTCHES.
3. Vehicles with automatic transmissions, remove the bolts, the flex-plate and the spacer plate.
4. Vehicles with manual transmissions, remove the flywheel.
5. On all vehicles, lower the vehicle.
6. Remove the nuts from the engine mounts. (Scheme 8)
7. Install the lifting eyes, the three-bar engine support and raise the engine 1.72" (43 mm). See «SPECIAL TOOLS»(ref-1331-S29620627442002120600000).
8. Install blocks between the engine mounts and the support brackets.
9. Raise the vehicle.
10. Remove the bolts and the oil pan. Discard the gasket.

Scheme 8

Disconnect negative battery cable. Remove dipstick. Raise and support vehicle. Remove oil level sensor connector. Drain oil. Disconnect oxygen senors and CMS sensor connectors. Remove dual-converter pipe and starter motor. Remove transaxle cover plate. Remove oil pan retaining bolts and oil pan. Remove oil pan gasket.

1. Thoroughly wash the oil pan and clean old sealer from all gasket surfaces with Metal Surface Cleaner F4AZ-19A536-RA or equivalent.
2. Apply silicone to the junction of the main bearing cap and the cylinder block and to the junction of the front cover assembly and the cylinder block. (Scheme 9)
3. Position the oil pan gasket to the cylinder block and secure it with Gasket and Trim Adhesive (F3AZ19B508-AA) or equivalent.
4. Position the oil pan and tighten the bolts in 5 stages: Stage 1: Tighten the 4 corner bolts to 80 INCH lbs. (12 N.m). Stage 2: Tighten the remaining bolts to 80 INCH lbs. (12 N.m). Stage 3: Tighten the four corner bolts to 80 INCH lbs. (12 N.m). Stage 4: Loosen all the bolts 1 turn. Stage 5: Tighten all the bolts to 80 INCH lbs. (12 N.m).
5. Lower the vehicle.
6. Remove the blocks from between the engine mounts and the support brackets.
7. Lower the engine and remove the three-bar engine supports and the lifting eyes.
8. Install the nuts.
9. Raise the vehicle.
10. Vehicles with manual transmissions, install the flywheel.
11. Vehicles with automatic transmissions, install the spacer plate, the flywheel and bolts.
12. All vehicles, install the transmission. For 1998-99 models with A/T, see «TRANSMISSION REMOVAL & INSTALLATION - TRUCKS»(ref-1146) article in TRANSMISSION SERVICING. For 2000 models with A/T, see «TRANSMISSION REMOVAL & INSTALLATION - LIGHT TRUCKS & VANS»(ref-97206) article in TRANSMISSION SERVICING. Remove clutch assembly (if equipped). For 1998-99 models, see «EXPLORER & RANGER»(ref-1367) article in CLUTCHES. For 2000 models, see «EXPLORER, EXPLORER SPORT, EXPLORER SPORT TRAC & RANGER»(ref-94680) article in CLUTCHES.
13. Install the air cleaner outlet tube.
14. Fill crankcase with engine oil.
15. Start engine and check for leaks.

Scheme 9

Removal (4WD)

1. Disconnect the battery ground cable.
2. Remove the front wheel and tire assembly.
3. Position the brake caliper aside. Remove the bolts. Separate the calipers from the rotors and position aside. (Scheme 10)
4. Unclip the left and right hand wheel speed sensor harness. (Scheme 11)
5. Remove the bolts and disconnect the upper ball joints. Pull the halfshafts away from the axle and position them aside. (Scheme 12)
6. Position and secure the front driveshaft. Remove the bolts. Separate the driveshaft from the axle. Secure the driveshaft. (Scheme 13)
7. Using the special tools, plug the axle ends. (Scheme 14)
8. Remove the 3 bolts. (Scheme 15)
9. Disconnect the vent hose and remove the axle housing from the vehicle. (Scheme 16)
10. Vehicles with automatic transmissions, lower the vehicle. Remove the nuts from the engine mounts. (Scheme 8)
11. Install the lifting eyes, the 3 bar engine support and raise the engine 1.72" (43 mm).
12. Install blocks between the engine mounts and the support brackets.
13. Raise the vehicle.
14. All vehicles, drain the engine oil.
15. Remove the 3 bolts and position the starter motor aside. (Scheme 17)
16. Remove the bolts and the oil pan. Discard the gasket.

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Installation (4WD)

1. Thoroughly wash the oil pan and clean old sealer from all gasket surfaces with Metal Surface Cleaner (F4AZ-19A536-RA) or equivalent.
2. Apply silicone to the junction of the main bearing cap and the cylinder block and to the junction of the front cover assembly and the cylinder block. (Scheme 9)
3. Position the oil pan gasket to the cylinder block and secure it with Gasket and Trim Adhesive (F3AZ19B508-AA) or equivalent.
4. Position the oil pan and tighten the bolts in the following 5 stages: Stage 1: Tighten the four corner bolts to 80 INCH lbs. (12 N.m). Stage 2: Tighten the remaining bolts to 80 INCH lbs. (12 N.m). Stage 3: Tighten the four corner bolts to 80 INCH lbs. (12 N.m). Stage 4: Loosen all the bolts 1 turn. Stage 5: Tighten all the bolts to 80 INCH lbs. (12 N.m).
5. Position the starter motor and install the 3 bolts. (Scheme 17)
6. Vehicles with automatic transmissions, lower the vehicle.
7. Remove the blocks from between the engine mounts and the support bracket.
8. Lower the engine and remove the 3 bar engine support and the lifting eyes and install the nuts. (Scheme 8)
9. Raise the vehicle.
10. All vehicles, remove the special tools.
11. Raise the axle housing, start the axle halfshafts into the axle and install the 3 bolts. (Scheme 15)
12. Remove the lift from the axle housing.
13. Position the front driveshaft and install the bolts. (Scheme 13)
14. Lower the vehicle.
15. Install the upper ball joints and the bolts. (Scheme 12)
16. Install the right and left hand wheel speed sensor harness. (Scheme 11)
17. Install the brake calipers and the bolts. (Scheme 10)
18. Install the front wheel and tire assemblies.
19. Connect the battery ground cable.
20. Fill crankcase.
21. Start engine and check for leaks.

1. Disconnect the air temperature sensor electrical connector. (Scheme 18)
2. Remove the crankcase ventilation tube. (Scheme 19)
3. Loosen the clamps and remove the air cleaner outlet tube. (Scheme 20)
4. To install, reverse removal procedure.

Scheme 18

Scheme 19

Scheme 20

1. Remove the disc and pressure plate.
2. Install a flywheel holding tool and remove flywheel-to-crankshaft bolts. Remove the flywheel. (Scheme 21)
3. Insect the flywheel for cracks, hot spots and scoring. If damage is found to the flywheel friction surface, machine flywheel surface. If damage is found to the ring gear teeth, replace ring gear.
4. Apply Threadlock and Sealer (EOAZ-19554-AA) or equivalent to flywheel-to-crankshaft bolt threads before installation.
5. Position the flywheel onto the crankshaft and install the flywheel-to-crankshaft bolts.
6. Tighten the bolts in sequence to torque specifications. (Scheme 22)

Scheme 21

Scheme 22

Removal & Disassembly

Remove oil pan. See OIL PAN under REMOVAL & INSTALLATION. Remove oil pump baffle. Remove oil pump retaining bolts. Remove oil pump and pick-up tube assembly. Remove oil pump drive shaft. Remove and replace gasket. Disassemble oil pump. Note direction of component installation for reassembly reference.

Reassembly & Installation

To reassemble, reverse disassembly procedure. Ensure components are installed in original location. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Fill crankcase.