2004 Ford Freestar SESFACTORY OEM SERVICE PROCEDURE

Engine Mechanical: Mechanical: Engine: Installation: Engine: Installation

  1. Position the engine onto the transaxle and subframe assembly.
  2. Install the engine mount bracket-to-transaxle bolts.
    Fig 1: Installing Engine Mount Bracket-To-Transaxle Bolts
    G03244191Courtesy of FORD MOTOR CO.
  3. Install the oil pan-to-transaxle bolt.
    Fig 2: Installing Oil Pan-To-Transaxle Bolt
    G03244192Courtesy of FORD MOTOR CO.
  4. Install the RH engine mount and bolt.
    Fig 3: Installing RH Engine Mount Bolt
    G03244193Courtesy of FORD MOTOR CO.
  5. Install the LH engine mount and bolt.
    Fig 4: Installing LH Engine Mount Bolt
    G03244194Courtesy of FORD MOTOR CO.
  6. Install the four bellhousing bolts.
    Fig 5: Installing Four Bellhousing Bolts
    G03244195Courtesy of FORD MOTOR CO.
  7. Install the transaxle fluid level indicator and tube and bolt.
    Fig 6: Installing Transaxle Fluid Level Indicator And Tube And Bolt
    G03244196Courtesy of FORD MOTOR CO.
  8. Attach the electrical connector to the subframe.
    Fig 7: Attaching Electrical Connector To Subframe
    G03244197Courtesy of FORD MOTOR CO.
  9. Attach the two electrical connectors to the wiring harness bracket.
    Fig 8: Attaching Electrical Connectors To Wiring Harness Bracket
    G03244198Courtesy of FORD MOTOR CO.
  10. Connect the electrical connectors.
    Fig 9: Connecting Electrical Connectors
    G03244199Courtesy of FORD MOTOR CO.
  11. Install the wiring harness pin-type retainer.
    Fig 10: Installing Wiring Harness Pin-Type Retainer
    G03244200Courtesy of FORD MOTOR CO.
  12. Connect the turbine shaft speed (TSS) sensor.
    Fig 11: Connecting TSS Sensor
    G03244201Courtesy of FORD MOTOR CO.
  13. Connect the transaxle electrical connectors.
    Fig 12: Connecting Transaxle Electrical Connectors
    G03244202Courtesy of FORD MOTOR CO.
  14. Install the wiring harness pin-type retainer.
    Fig 13: Installing Wiring Harness Pin-Type Retainer
    G03244203Courtesy of FORD MOTOR CO.
  15. Position the engine roll restrictor bracket and install the bolts.
    Fig 14: Positioning Engine Roll Restrictor Bracket
    G03244204Courtesy of FORD MOTOR CO.
  16. Install the engine wiring harness into the retainers.
    Fig 15: Installing Engine Wiring Harness Into Retainers
    G03244205Courtesy of FORD MOTOR CO.
  17. Attach the electrical connector to the subframe.
    Fig 16: Attaching Electrical Connector To Subframe
    G03244206Courtesy of FORD MOTOR CO.
  18. Install the engine wiring harness into the retainer.
    Fig 17: Installing Engine Wiring Harness Into Retainer
    G03244207Courtesy of FORD MOTOR CO.
  19. Install the A/C compressor.
    • Position the A/C compressor.
    • Install the bolts.
    Fig 18: Installing A/C Compressor
    G03244208Courtesy of FORD MOTOR CO.
  20. connect the A/C compressor electrical connector.
    Fig 19: Connecting A/C Compressor Electrical Connector
    G03244209Courtesy of FORD MOTOR CO.
  21. Install the generator brace bolt.
    Fig 20: Installing Generator Brace Bolt
    G03244210Courtesy of FORD MOTOR CO.
  22. Using a 19-mm (0.76 -in) dowel, check the front subframe alignment.
    • The dowel should slide directly through the front subframe and body without tilting.
    Fig 21: Checking Front Subframe Alignment
    G03244211Courtesy of FORD MOTOR CO.
  23. Using the special tool, raise the engine, transaxle and subframe assembly in the vehicle.
    Fig 22: Raising Engine Transaxle And Subframe Assembly
    G03244212Courtesy of FORD MOTOR CO.
  24. Install the four subframe bolts.
    Fig 23: Installing Four Subframe
    G03244213Courtesy of FORD MOTOR CO.
  25. Install the RH and LH strut bolts.
    Fig 24: Installing RH And LH Strut Bolts
    G03244214Courtesy of FORD MOTOR CO.
  26. Connect the RH and LH front stabilizer links and install the nuts.
    Fig 25: Connecting RH And LH Front Stabilizer Links
    G03244215Courtesy of FORD MOTOR CO.
  27. Connect the RH and LH anti-lock brake sensor (ABS) electrical connectors.
    Fig 26: Connecting RH And LH ABS Electrical Connectors
    G03244216Courtesy of FORD MOTOR CO.
  28. Install the RH and LH ABS sensor wiring harness retainers.
    Fig 27: Installing RH And LH ABS Sensor Wiring Harness
    G03244217Courtesy of FORD MOTOR CO.
  29. Install the RH and LH brake calipers.
    • Install the bolts.
    Fig 28: Installing RH And LH Brake Calipers
    G03244218Courtesy of FORD MOTOR CO.
  30. Install the four torque converter nuts.
    Fig 29: Installing Four Torque Converter
    G03244219Courtesy of FORD MOTOR CO.
  31. Install the inspection cover.
    • Install the bolt.
    Fig 30: Installing Inspection Cover
    G03244220Courtesy of FORD MOTOR CO.
  32. Install the oil pan-to-transaxle bolts.
    Fig 31: Installing Oil Pan-To-Transaxle
    G03244221Courtesy of FORD MOTOR CO.
    33. NOTE: RH shown; LH similar.
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.