How to remove Automatic Transaxle Engine on 2003 Ford Focus?

Removal & Installation

Automatic Transaxle
2.0L DOHC Engine (VIN 3 And VIN 5)

1. Before servicing the vehicle, refer to the Precautions Section.
2. Drain the cooling system.
3. Relieve the fuel system pressure.
4. Loosen the front strut center nuts 5 turns.
5. Remove or disconnect the following:
   
   
   Battery, tray and cables

   Mass Air Flow (MAF) sensor connector

   Positive Crankcase Ventilation (PCV) valve and hose

   Air cleaner assembly and tubes

   Accelerator cable

   Cruise control cable, if equipped

   Ignition coil connectors

   Heated Oxygen (HO ₂ S) sensor connectors

   Fuel injector harness connectors

   Powertrain Control Module (PCM) connectors

   Radiator cooling fan

   Evaporative Emissions (EVAP) canister vacuum lines

   Power brake booster vacuum line

   Delta Pressure Feedback Electronic (DPFE) system sensor vacuum line

   Exhaust Gas Recirculation (EGR) vacuum line

   Intake manifold vacuum line

   Fuel line

   Coolant bypass hoses

   Radiator hoses

   Coolant expansion tank

   Shift select cable and bracket

   Transaxle fluid cooler lines

   Drive belt cover

   Power steering pressure switch connector

   Accessory drive belt

   A/C compressor, if equipped

   Power steering pump

   Power steering pressure pipe

   Exhaust flex pipe

   Right engine mount

   Lower ball joints

   Axle halfshafts and intermediate shaft
6. Support the powertrain from below
7. Remove the front and rear engine mounts.
8. Raise the vehicle away from the powertrain.

To install:

1. Lower the vehicle over the powertrain.
2. Install or connect the following:
   
   
   Front engine mount. Tighten the nuts to 59 ft. lbs. (80 Nm) and the bolts to 35 ft. lbs. (48 Nm).

   Rear engine mount. Tighten the outer nuts to 35 ft. lbs. (48 Nm) and the center nut to 98 ft. lbs. (133 Nm).

   Axle halfshafts and intermediate shaft

   Lower ball joints. Tighten the pinch bolts to 37 ft. lbs. (50 Nm).

   Right engine mount. Tighten the bolts to 35 ft. lbs. (48 Nm).

   Exhaust flex pipe

   Power steering pressure pipe

   Power steering pump

   A/C compressor, if equipped

   Accessory drive belt

   Power steering pressure switch connector

   Drive belt cover

   Transaxle fluid cooler lines

   Shift select cable and bracket

   Coolant expansion tank

   Radiator hoses

   Coolant bypass hoses

   Fuel line

   Intake manifold vacuum line

   EGR vacuum line

   DPFE system sensor vacuum line

   Power brake booster vacuum line

   EVAP canister vacuum lines

   Radiator cooling fan

   PCM connectors

   Fuel injector harness connectors

   HO ₂ S sensor connectors

   Ignition coil connectors

   Cruise control cable, if equipped

   Accelerator cable

   Air cleaner assembly and tubes

   PCV valve and hose

   MAF sensor connector

   Battery, tray and cables
3. Tighten the strut center nuts to 35 ft. lbs. (48 Nm).
4. Fill the cooling system.
5. Start the engine and check for leaks.

2.0L SOHC Engine (VIN P)

1. Before servicing the vehicle, refer to the Precautions Section.
2. Drain the cooling system.
3. Relieve the fuel system pressure.
4. Loosen the front strut center nuts 5 turns.
5. Remove or disconnect the following:
   
   
   Battery, tray and cables

   Mass Air Flow (MAF) sensor connector

   Air cleaner housing and tubes

   Accelerator cable

   Cruise control cable, if equipped

   Ignition coil connectors

   Power steering pump pressure switch connector

   Heated Oxygen (HO ₂ S) sensor connectors

   Fuel injection wiring harness connector

   Powertrain Control Module (PCM) connectors

   Radiator cooling fan

   Evaporative Emissions (EVAP) canister vacuum lines

   Power brake booster vacuum line

   Delta Pressure Feedback Electronic (DPFE) system sensor vacuum line

   Exhaust Gas Recirculation (EGR) vacuum line

   Intake manifold vacuum line

   Fuel line

   Coolant bypass hoses

   Radiator hoses

   Coolant expansion tank

   Accessory drive belt

   Power steering pump and reservoir

   Power steering high pressure pipe

   Alternator and bracket

   Drive belt cover

   A/C compressor, if equipped

   Lower ball joints

   Exhaust front pipe

   Torque converter cover

   Torque converter

   Transaxle fluid cooler lines

   Axle halfshafts

   Intermediate shaft bracket

   Starter motor

   Crankshaft pulley

   Right engine mount

   Transaxle flange bolts. Support the transaxle

   Engine front mount

   Crankshaft Position (CKP) sensor

   Engine

To install:

1. Install or connect the following:
   
   
   Engine

   CKP sensor

   Engine front mount. Tighten the nuts to 59 ft. lbs. (80 Nm) and the bolts to 35 ft. lbs. (48 Nm).

   Transaxle flange bolts. Tighten the large bolts to 35 ft. lbs. (48 Nm) and the small bolts to 16 ft. lbs. (22 Nm).

   Right engine mount. Tighten the bolts to 35 ft. lbs. (48 Nm).

   Crankshaft pulley. Tighten the bolt to 88 ft. lbs. (120 Nm).

   Starter motor

   Intermediate shaft bracket. Tighten the bolts to 35 ft. lbs. (48 Nm).

   Axle halfshafts

   Transaxle fluid cooler lines

   Torque converter. Tighten the nuts to 27 ft. lbs. (37 Nm).

   Torque converter cover

   Exhaust front pipe

   Lower ball joints. Tighten the pinch bolts to 37 ft. lbs. (50 Nm).

   A/C compressor, if equipped

   Drive belt cover

   Alternator and bracket

   Power steering high pressure pipe

   Power steering pump and reservoir

   Accessory drive belt

   Coolant expansion tank

   Radiator hoses

   Coolant bypass hoses

   Fuel line

   Intake manifold vacuum line

   EGR vacuum line

   DPFE system sensor vacuum line

   Power brake booster vacuum line

   EVAP canister vacuum lines

   Radiator cooling fan

   PCM connectors

   HO ₂ S sensor connectors

   Fuel injection wiring harness connector

   Power steering pump pressure switch connector

   Ignition coil connectors

   Cruise control cable, if equipped

   Accelerator cable

   Air cleaner housing and tubes

   MAF sensor connector

   Battery, tray and cables
2. Tighten the strut center nuts to 35 ft. lbs. (48 Nm).
3. Fill the cooling system.
4. Start the engine and check for leaks.

2.3L Engine (VIN Z)

1. Before servicing the vehicle, refer to the Precautions Section.
2. With the vehicle in NEUTRAL, position it on a hoist.
3. Release the fuel system pressure.
4. Remove the battery tray.
5. Recover the A/C system.
6. Drain the cooling system.
7. Drain the engine oil. Install the drain plug.
8. Remove the accessory drive belt.
9. Remove the catalytic converter.
10. Remove the air intake resonator.
11. Disconnect the fuel tube.
12. Disconnect the vapor tube.
13. Disconnect the engine emissions hose and the exhaust gas recirculation (EGR) vacuum regulator solenoid electrical connector.
14. Disconnect the brake booster vacuum hose.
15. Disconnect the lower radiator hose, the heater hose and the overflow hose from the coolant bypass.
16. Disconnect the hose, remove the screw and the pin-type retainer.
17. Remove the snow shield.
18. Position aside the accelerator cable and speed control cable (if equipped).
19. Disconnect the accelerator and speed control cable (if equipped) from the throttle body.
20. Remove the three bolts and position aside the accelerator cable bracket aside.
21. Disconnect the fuel injection supply manifold wiring harness electrical connector.
22. Disconnect the EGR valve electrical connector.
23. Disconnect the heater hose from the "T" fitting and position it aside.
24. Remove the coolant expansion tank.
25. Disconnect the power steering pressure (PSP) switch electrical connector.
26. Remove the power steering pump pulley.
27. Disconnect the PSP tube.
28. Disconnect the three main engine wiring harness electrical connectors.
29. Remove the wiring harness retainers from the valve cover.
30. Disconnect the cooling fan electrical connector.
31. Disconnect the upper radiator hose.
32. Remove the battery cable bracket nut.
33. Remove the generator heat shield top nut.
34. Remove the generator B+ cable nut and disconnect the B+ cable.
35. Remove the bolt and the ground cable.
36. Remove the generator cooling tube.
37. Disconnect the transmission shifter cable and position it aside.
38. Disconnect the transmission cooler hoses.
39. Remove the cooling fan.
40. Remove the two lower bellhousing bolts.
41. Remove the two oil pan-to-bellhousing bolts.
42. Disconnect the starter electrical connections.
43. Remove the nuts and disconnect the power steering pressure line brackets from the stud bolts.
44. Remove the three A/C compressor bolts.
45. Loosen the bolt and remove the A/C compressor.
46. Lower the A/C compressor to access the manifold bolt. Discard the O-ring seals.
47. Disconnect the field coil electrical connector.
48. Disconnect the LH brake hose from the support bracket.
49. Disconnect the LH caliper.
    
    CAUTION

    Suspend the caliper to prevent load from being placed on the brake hose.
50. Support the brake caliper.
51. Loosen the LH strut and spring assembly top mount nuts by four turns.
52. Disconnect the LH stabilizer bar at the strut.
53. Remove the LH tie-rod end nut.
54. Remove the RH tie-rod end nut.
55. Disconnect both of the tie-rods from the knuckles.
56. Disconnect both of the lower control arms from the knuckles.
57. Remove the mounting bracket nuts, then remove the bracket from the halfshaft intermediate bearing.
58. Remove the RH front drive halfshaft. Position the halfshaft aside and support with mechanic's wire.
59. Install a plug into the transaxle opening.
60. Remove the LH front drive halfshaft from the transaxle.
61. Install a plug into the transaxle opening.
62. Support the halfshaft using mechanic's wire.
63. Remove the lower engine mount.
64. Remove the three bolts and the starter.
65. Remove the starter isolator.
    
    NOTE

    Mark one stud and the flexplate for assembly reference.
66. Remove the four torque converter nuts.
67. Fasten the engine to the lift table.
68. Remove the RH motor mount nuts.
69. Remove the LH motor mount nut.
70. Lower the engine and transaxle assembly from the vehicle.
71. Disconnect the output shaft speed (OSS) sensor electrical connector.
72. Disconnect the turbine shaft speed (TSS) sensor electrical connector.
73. Disconnect the solenoid body and the transmission range (TR) sensor electrical connectors.
74. Separate the transaxle from the engine.

To install:

Fig. Use a straight edge (1) to check the torque converter installed depth (2)-2.3L engine

NOTE

Lubricate the torque converter pilot hub with multi-purpose grease.

1. Check the installation depth of the torque converter. Lay a steel straightedge on the automatic transaxle flange. Check the installation depth between the transaxle flange and the torque converter centering spigot for the correct clearance. The dimension should be 0.60-0.71 inches (15-18 mm).
2. Position the engine and transaxle together and install five of the six top bolts.
   
   NOTE

   Make sure to note the location of the different length bolts.
3. Install the LH flange bolts and tighten to 35 ft. lbs. (47 Nm).
4. Connect the output shaft speed (OSS) sensor electrical connector.
5. Connect the solenoid body and the transmission range (TR) sensor electrical connectors.
6. Connect the turbine shaft speed (TSS) sensor electrical connector.
7. Using the lift table, position the engine and transaxle assembly in the vehicle.
8. Install the RH motor mount nuts and tighten them to 59 ft. lbs. (80 Nm).
9. Install the LH motor mount nut and tighten it to 98 ft. lbs. (133 Nm).
10. Remove the lift table.
11. Install the lower motor mount. Tighten the bolts to 35 ft. lbs. (48 Nm).
12. Install the two lower engine-to-bellhousing bolts and tighten them to 35 ft. lbs. (48 Nm).
13. Install the remaining engine-to-bellhousing bolts and tighten them to 35 ft. lbs. (48 Nm).
    
    NOTE

    If new parts are not being used, be sure to align the marks on the flexplate and the stud made during engine removal.
14. Install the four torque converter nuts and tighten them to 27 ft. lbs. (37 Nm).
15. Install the starter motor isolator.
16. Install the starter motor and tighten the bolts to 18 ft. lbs. (25 Nm).
17. Install the generator heat shield and the lower nut.
    
    NOTE

    Install new O-ring seals.
18. Position the A/C compressor to the manifold and tube assembly and tighten the bolt to 15 ft. lbs. (21 Nm).
19. Install the A/C compressor and tighten the three bolts to 18 ft. lbs. (21 Nm).
20. Connect the field coil electrical connector.
21. Attach the power steering pressure tube brackets to the stud bolts and install the nuts.
22. Connect the starter motor electrical connections.
23. Install the cooling fan.
24. Connect the transmission cooler hoses.
25. Connect the transmission shifter cable.
26. Position the battery cable and install the cable bracket nut.
27. Install the generator cooling tube.
28. Install the generator heat shield top nut.
29. Install the generator B+ cable and install the cable nut.
30. Install the upper radiator hose.
31. Position the ground cable and install the bolt.
32. Connect the cooling fan electrical connector.
33. Connect the cooling fan electrical connector.
34. Connect the wiring harness retainers to the valve cover studs.
35. Position the power steering pump (PSP) and install the bolts.
36. Connect the PSP tube.
    
    NOTE

    Make sure the pulley is flush with the end of the power steering pump shaft.
37. Install the power steering pump pulley.
38. Connect the PSP switch electrical connector.
39. Connect the three main engine wiring harness connectors.
40. Install the coolant expansion tank.
41. Connect the heater hose to the "T" fitting.
42. Connect the exhaust gas recirculation (EGR) valve electrical connector.
43. Connect the fuel injection supply manifold wiring harness electrical connector.
44. Position the accelerator cable bracket.
45. Install the speed control cable (if equipped) and the throttle cable.
46. Attach the hose and install the screw and the pin-type retainer.
47. Install the snow shield.
48. Install the catalytic converter.
49. Connect the lower radiator hose, the heater hose and the overflow hose to the coolant bypass.
50. Connect the engine emissions hose and EGR vacuum regulator solenoid electrical connector.
51. Install the vapor tube.
52. Connect the fuel tube.
53. Install the brake booster vacuum hose.
54. Fill the engine with clean engine oil.
    
    NOTE

    Install a new snap ring.
55. Install the LH front drive halfshaft.
    
    NOTE

    Install new nuts and a new center bearing cap.
56. Install the RH front halfshaft together with the intermediate shaft.
57. Install the mounting bracket for the front drive halfshaft intermediate bearing.
58. Install both of the lower control arms to the knuckles. Tighten the bolts to 37 ft. lbs. (50 Nm).
59. Install both of the tie-rod ends to the knuckles. Tighten the nuts to 35 ft. lbs. (47 Nm).
60. Connect the stabilizer bar at the strut.
61. Tighten the LH strut and spring assembly top mount nuts to 18 ft. lbs. (25 Nm).
62. Install the brake caliper. Tighten the bolts to 21 ft. lbs. (28 Nm).
63. Install the brake hose onto the support bracket.
64. Install the accessory drive belt.
65. Evacuate and recharge the A/C system.
66. Install the air intake resonator.
67. Install the battery tray.
68. Connect the battery ground cable.
69. Fill and bleed the cooling system.
70. Fill and bleed the power steering system.

-----------