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

Posted: Tue Aug 06, 2019 11:56 am
by K4uwc
I've very thankful to be able to come here and find most answers about the Freestyle. I got an '05 Limited that's pretty much junk and I'm disassembling it. The main purpose is to practice removing the transmission if/when I need to do that to my '07 SEL. I also like seeing how everything is put together and plan to save some useful parts for the '07.

I thought I'd start a thread to post pictures. I would love for anyone out there to ask questions about how to do various operations. If I haven't taken it apart yet but you'd like to know something then I can try and take pictures for you. Maybe you'd like to know what a connector looks like or the size of a bolt that was used to attach a component. Or the backside of a component that you can't see since it's installed in your car. Let me know while I still have the car.

I plan to save a lot but if there are miscellaneous things you could use then ask. Most of the interior will go with the car to the salvage yard and I don't plan to keep any body panels. Holler if you need something like seatbelts or window motor or small items that are easily shipped as I'd like to help out. We don't have junk yards around here where you pick your own parts so small things like needing a dipstick or a connector usually have to be sourced online.

Background: the car has 200k+ miles and the person that had it tried to put in a used transmission. He never got it to work so he gave it to me plus the original. I never saw the vehicle run so I have no clue what is wrong. I'm taking the transmissions apart to look for obvious damage. So far the input shafts looks pretty clean. My nice '07 has the noise in P and N so holding onto the input shafts could help me out in the future on that car. So far I've harvested the homelink, window vent deflectors, and drawtite hitch from the junk car onto my nice one.

Black car = '05 limited (junk) Blue/green = '07 SEL (nice) Both AWD

These are some random pics of my progress to date. I'll be continuing to disassemble it over the next couple of weeks so please comment on what I've already done or something new you'd like me to look into. I'm very careful about the disassembly as I'm not just chopping harnesses and bolts. I'm saving everything as if I were to use it on my other car.

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

Posted: Tue Aug 06, 2019 12:15 pm
by Webmaster
The engine looks very clean under the valve cover, I bet someone used full synthetic oil in that engine!!

What's the aluminum foil over the brake fluid reservoir for I wonder??

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

Posted: Tue Aug 06, 2019 12:56 pm
by K4uwc
I've love to hear your comments. Please point out anything you find unusual. I've noted a few things like spliced wires and other things I would keep an eye on if I were to reuse some parts but may you see things and can point them out so we all can learn.

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

Posted: Tue Aug 06, 2019 1:01 pm
by K4uwc
More random pics. Sorry everything isn't in chronological order or labeled

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

Posted: Tue Aug 06, 2019 1:07 pm
by K4uwc
You can see the interior isn't bad. Seats look very good for 200k miles. Heated seats, DVD (maybe broken?), and moon roof although I can't use any of it in my '07. The middle row are separate seats with the console which I know can be desirable but it's not the same color so I can't use it on my '07.

I've been in the dash today mostly pulling out the wiring harness. Luckily there was never an aftermarket radio or alarm or remote start so everything is from the factory. I put all the screws and bolts back where they came from even though I will never reassemble the car. I'll probably do a sweep through the vehicle and take those out before it gets scrapped to save them if I ever need an misc fastener in the future.

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

Posted: Tue Aug 06, 2019 1:14 pm
by K4uwc
Removing the transmission through the top wasn't too hard. I'd rate my mechnical skills at 3.5 out of 5. Getting the PTU out was probably the biggest challenge due to the location of the bolts. First the knock sensor came out and you have very little room to work to swing the wrench so luckily it wasn't stuck. I did all this on jack stands with help from a floor jack to move things around and eventually a 2 ton lift from harbor freight to do the heaving lifting. I also had to take off the master cylinder as I couldn't get clearance with it in place and despite other posts I couldn't find a way to push it aside enough to make room. I didn't want to bend any brake lines so the master came off. I had a little difficulty getting the torque converter bolts off. I think I only had to cut one bolt off in getting the transmission out and that was the big ground cable next to the starter. However when I remove the engine I had to cut off one of the exhaust to catalytic converter bolts as it was rounded. Another casualty along the way was a pinched line on the driver side frame rail. I can't remember if it was power steering or transmission but when the CVT was loose I let it down and it sat on the line and kinked it. One of the drive (half) shafts broke when it was removed so knowing that plus a new line plus the car having rust in the rear quarter were all reasons not to try to revive the car and get it on the road.

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

Posted: Tue Aug 06, 2019 1:21 pm
by K4uwc
Someone soldered the main engine harness and bypassed the connector. This is the one above the radiator in front of the engine. I saw a few scary things like that which made me worry. Even though I noted it didn't have any aftermarket stuff I still saw some modifications that caused concern. There was a button on the column that appeared to be a neutral override switch as the connector for the starter had been cut. The starter was off the car so I don't know how they had it wired. They also had cut wires going to the fog lights which had been zip-tied on.

I did hook up the battery and most things worked. Radio and HVAC. The only window that didn't operate was the passenger front. I hooked up my OBD reader and it just said Connecting... and could never read any codes or information from the computer. I didn't put any effort into that to understand if it was a fuse or something more serious. With the key on (and with the intake off and fuel hose not connected) it would try to prime the fuel rails and spit out gas so the fuel system seemed to be OK.

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

Posted: Tue Aug 06, 2019 1:29 pm
by K4uwc
I had posted a few pics in other topics. One asked about the bracket on the PTU. It's interesting the PTU in the car had no bracket or mounting holes for one. The PTU that I believe to be original and came with the original transmission had the bracket. I checked my '07 and it did not have a bracket.

It's nice to have the same car to check but obviously Ford was making engineering changes along the way.

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

Posted: Tue Aug 06, 2019 1:32 pm
by K4uwc
Webmaster wrote:
Tue Aug 06, 2019 12:15 pm
The engine looks very clean under the valve cover, I bet someone used full synthetic oil in that engine!!

What's the aluminum foil over the brake fluid reservoir for I wonder??
HI Webmaster. Great question! I noticed it but assumed it was some factory heat shield even though it looked a little sketchy. There was no such thing on my '07.

I went out to the garage and found the answer. It covered a hole! I bet it happened when they were putting the transmission in. Although I saw one of the cradle bolts was missing which made me think they lowered the transmission as Ford recommends rather than take it out the top.

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

Posted: Tue Aug 06, 2019 9:25 pm
by mburns31
I'm in need of a few parts. Was wondering what you would charge. Need the oil pressure sensor for the halidex awd unit, rear window wiper motor and wanted to see if you had a key fob that was extra that came with the scrap car?

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

Posted: Wed Aug 07, 2019 7:34 am
by jas88
Would you be willing to sell me the visor with the 3 buttons on it?

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

Posted: Wed Aug 07, 2019 11:21 am
by K4uwc
If you see a part you may need then please send a personal message. The primary point of this thread is to document the tear down and help those that may be about to tackle a project but not sure how to go about it. I'd like to pass on as much information as I can while it's apart.

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

Posted: Sat Aug 10, 2019 4:10 pm
by K4uwc
I made a lot of progress today on the interior. Stripped most of the plastic panels out and ended with pulling out the dash. The dash wasn’t as hard to get out as I had thought. It was heavy but I can handle it by myself. I left the front seats in but unbolted the bar and moved the front seat back as far as possible. In hindsight I should’ve Removed the seats as recommended by Ford. I scraped the lower part of the dash when extricating it out the passenger door. I take it out the door seal so the plastic dash scraped on metal. If I were doing a nice car I’d definitely protect the dash better. Having an extra set of hands would also be nice.

I also took out the rear HVAC on the driver side and what I think is the subwoofer on the passenger side.

I removed the entire wiring harness from the dashboard forward.

The only thing I didn’t finished was popping off the rear view mirror. I don’t want to put too much force on it.

Questions and comments are welcome. The goal is just to take things off a vehicle bound for the junkyard, save some parts of value, and learn as much as possible in the process

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

Posted: Sat Aug 10, 2019 4:17 pm
by K4uwc
A few more interior pics...

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

Posted: Sun Aug 11, 2019 4:37 pm
by K4uwc
Tips on removing the rear view mirror? I’m still looking for one. I spent a lot of time reading how people have remove them. The Ford manual didn’t make much sense. So I felt like I was lightly prying up on the springs (metal clips) but the glass separated taking the mirror with it. Junk car so I don’t care but I need to learn in case I have to do it on a nice car. The windshield didn’t crack. Just a chunk of it came with the mirror.