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Disassembly diary... '05 Limited Anyone need anything?

K4uwc
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Re: Disassembly diary... '05 Limited Anyone need anything?

Post by K4uwc » Sun Aug 11, 2019 4:40 pm

I’m figuring how to use pliers to press the clips to release the mounting bracket
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mmsstar
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Re: Disassembly diary... '05 Limited Anyone need anything?

Post by mmsstar » Mon Aug 12, 2019 3:53 am

There is a special tool for that
Drove an 06 LTD FWD from July 08 to August 10, moved on to a 2011 Flex

K4uwc
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Re: Disassembly diary... '05 Limited Anyone need anything?

Post by K4uwc » Mon Aug 12, 2019 6:41 am

According to the manual... no tool is needed. 10 lbs of pressure with your hand they claim.

I used a trim pry tool and wasn't forceful. I thought I was depressing the clips and the mirror would slide off. The bond of the epoxy to the windshield was stronger than the upward force I was applying to separate the mirror from the metal bracket.

Looks like this would be helpful: https://www.amazon.com/CTA-Tools-A581-R ... way&sr=8-2

K4uwc
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Re: Disassembly diary... '05 Limited Anyone need anything?

Post by K4uwc » Mon Aug 12, 2019 6:02 pm

Out with the seats. Lots of room in there with no front seats or dash! Maybe I’ll give them to the neighbor kids to put in their tree house. Too bad someone doesn’t want this roller shell to drop in a 4.6L.
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K4uwc
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Re: Disassembly diary... '05 Limited Anyone need anything?

Post by K4uwc » Mon Aug 12, 2019 6:07 pm

Taking out the antenna. Super easy without a dash.
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K4uwc
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Re: Disassembly diary... '05 Limited Anyone need anything?

Post by K4uwc » Wed Aug 14, 2019 3:02 pm

I soaked the mirror spring clip with WD40 and it finally moved using pliers so I could remove the metal piece normally stuck to the windshield. I had to be careful because the piece of glass still attached to a sharp so when you slip trying to pry the metal piece out would not of ended well.

Now on to the rear including pulling the driveshaft, halfshafts, brakes, fuel pump. So far the metal ring on the fuel pump is being stubborn so it’s soaking in PB blaster.
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K4uwc
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Re: Disassembly diary... '05 Limited Anyone need anything?

Post by K4uwc » Fri Aug 16, 2019 4:50 pm

Exhaust is out. One of the fasteners was rusted and there was almost no way I could get it out without serious work. So I decided to take the entire exhaust out as a unit (I did get the front catalytic converter separated before pulling it all out from under the car)

The cats look clean inside but I’m not sure what a clogged cat looks like but know if can be a problem.

Does anyone have a request for any pictures? I’d be glad to show you something that could help with your car.

Next steps are to take out the rear driveshaft and half shafts. I’m still struggling to get the lock ring off the tank in order to remove the pump.
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K4uwc
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Re: Disassembly diary... '05 Limited Anyone need anything?

Post by K4uwc » Sat Aug 17, 2019 12:57 pm

It’s so much easier without the engine and transmission! I wanted to take out the sub frame to see how I could coordinate using two jacks and a furniture dolly. If I could figure out the right sequence then it’ll will be much easier once I try it with the engine and CVT. I know that a line in it with the body and lifting it into place or the body down on it will be difficult.
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K4uwc
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Re: Disassembly diary... '05 Limited Anyone need anything?

Post by K4uwc » Tue Aug 20, 2019 3:12 pm

Time to tackle rust. One of the studs on the catalytic converter had to be cut to get it off. So while the engine is out I thought this would be a good time to try to get that out. I first tried with the exhaust manifold on the engine with no luck. So risking more problems I decided to take the exhaust manifold off knowing those studs could also break. They all came out without too much trouble. Some of the studs came out but I could separate them from the nut easily. I soaked it in PB blaster, used heat, and tried melting wax in the threads. No luck. My vice grips don’t have enough clamping pressure or sharp teeth. The reason I’m doing this is to learn so that project will sit until I figure out what to do next. New vice grips are probably the answer.

The other things I’m having trouble with our getting the lock ring off the fuel pump and getting the driveshaft bolts off. The driveshaft spins freely which makes it difficult to put toward on those bolts. I got a strap wrench that will keep the driveshaft from turning however the torx 45 bit used on the driveshaft plus width of the ratchet is too much to seat exactly my in the head of the bolt. The ratchet hits the drive shaft causing a slight angle of the bed into the head. I know I will strip out the head if I try to put much pressure on it. I know the bolts aren’t torqued a lot but it’s harder to get them out than it should be. I even tried to use vice grips around the head of the bolt but again my vice grips don’t have enough grip to do the job.

I’ll figure it out but for now those are the hurdles
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K4uwc
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Re: Disassembly diary... '05 Limited Anyone need anything?

Post by K4uwc » Fri Aug 23, 2019 7:17 pm

I drilled out the exhaust stud and wiped out several drillbits in the process. But this is a learning experience so that’s OK. I put the engine back on the sub frame. With intentions of only trying to start the engine I bolted on the torque converter cover a.k.a. bell housing. This will allow me to mount the starter. I’m putting the wiring back on as well as some of the other engine parts I had taken off.

PS - it says I’ve reached the board attachment quota so no more pics for now

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Re: Disassembly diary... '05 Limited Anyone need anything?

Post by Webmaster » Fri Aug 23, 2019 10:59 pm

Limit bumped

K4uwc
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Re: Disassembly diary... '05 Limited Anyone need anything?

Post by K4uwc » Sat Aug 24, 2019 7:37 am

Thanks Webmaster!

I hope everyone is enjoying the pictures. Please ask if you have any questions or would like to see something I have not shown yet.
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K4uwc
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Re: Disassembly diary... '05 Limited Anyone need anything?

Post by K4uwc » Sat Aug 24, 2019 7:46 am

I lifted it using the exhaust manifold as lifting points. It was a little tricky with only two points as the engine wanted to rock but it wasn’t too hard to get the engine mount studs on to the sub frame.

Here it is mostly ready to start. I need to hook up the grounds and starter circuit. You can see the damage to the bellhousing and the roll resistor bracket is also broken.

The fuel pump ring was very difficult to get off. Here’s a picture where I made a slot in a screwdriver to locate it on the ring is I used a hammer. I soaked it in PB blaster and it eventually started to turn.
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K4uwc
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Re: Disassembly diary... '05 Limited Anyone need anything?

Post by K4uwc » Thu Aug 29, 2019 9:40 am

Progress is getting slow. I quickly hooked up the harness to the engine to see if I could turn the starter using the ignition key. The instrument cluster didn’t light so I need to start tracing wires. I’m almost positive I missed a ground or two. I left the ignition key in the dash for now.

I have lots of questions about the minimum number of inputs the computer needs to start the engine. For instance does it have to see the accelerator pedal is connected? I’m hooking up most things I think are necessary.

The only thing left to get the harness out from the rear is a connector I cannot see. The harness goes through a hole in the interior past the fuel pump. From there it’s a mystery in the entire interior harness can’t be removed unless I get that connection off. I think the only way is to drop the tank. However to do that I need to get the driveshaft out and that’s becoming a problem. The torques bolts are out but the driveshaft is stuck to the flange. I’ve used a set of locking pliers on the driveshaft and then a hammer to try to drive it out (towards front of car) but no luck. I’ll keep after it.
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K4uwc
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Re: Disassembly diary... '05 Limited Anyone need anything?

Post by K4uwc » Fri Aug 30, 2019 6:28 pm

I got the driveshaft out. However it was stuck To the active on demand coupling. So I just remove the four bolts that held the a AOD to the differential and took it off. Then separated it from the driveshaft. Two of the ball bearings came out of the driveshaft when separated. I assume this is not normal. I just know that the driveshaft did not want to come free from the flange in with very little room under the car to work then it was best done pulling it along with the AOD.

They gave me access to the wiring harness that goes from the cabin through the floor to the rear. It was difficult to get it free because of the plastic fasteners holding it to the body but with persistence I got it without any damage.

Here is the central nervous system of the Freestyle with everything that connects to the dash and rearward. Along with the AOD and driveshaft.

As always please ask questions if you have any specific components you’d like me to take a picture of
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