How do you remove the transmission on a 2002 Mercury Cougar V6?

Answer 1

Disconnect battery - and + cables from battery

Remove battery tie-down and battery from car

Unbolt Battery tray from car

Remove intake system (air box) up to throttle body

Disconnect wiring harness from upper part of MTX (reverse lights, vss, O2 sensors and move up out of way)

Remove starter wiring from starter

Remove starter

Remove Clutch Slave Cylinder line (pull clip out first), plug line, and raise up out of way near Brake fluid resevoir

Raise Vehicle on suitable stands (lift, ramps, etc)

Remove front wheels

Remove Passenger side splash guards and front bumper lower guard

Drain MTX fluid via drain plug

Unbolt and move to side lower steering joint to steering rack at bottom of steering column (1-10mm bolt)

Drain Power Steering fluid via P.S. cooler lines

Disconnect P.S. lines from steering pump (plug lines whenever possible to prevent excess fluid spillage)

Remove P.S. resevoir and disconnect lower hose

Slide both lines down behind alternator as much as possible to be ready for subframe lowering

Remove Y-pipe and Catalytic converter from exhaust system

Unbolt Tie rod end nuts from knuckles

Unbolt Sway bar end links from struts

Remove ball joint pinch bolts from knuckles

Remove rear Trans mount Bolts and Mount from underside of subframe

Remove front trans mount from subframe and MTX

Support subframe with suitable jack

Unbolt 4-21mm bolts for subframe (subframe will hang from ball joints at knuckles)

Lower subframe with jack and pop ball joints from knuckles

Remove subframe from under car, paying attention to P.S. lines (as mentioned earlier)

Remove Axle from driver side of MTX, and hang it to the side of wheel well with a bungee or wire

Remove half shaft from bracket (2-13mm nuts)

Slide Passnger axle/half shaft from MTX and hang to side with bungee or wire

Remove 2-15mm nuts for shift cable bracket to MTX

Pop shift cable ends from shift tower, slide cables while attached to bracket as far towards firewall as possible to clear MTX

Verify that all electrical connectors have been disconnected from MTX

Support engine with support bar, or large jack (ideal to place large piece of wood under oil pan to prevent damage)

Place a Jack (ideally a transmission jack) under MTX

Remove MTX-to-Engine bolts

Slowly and carefully pry MTX away from engine

Once MTX is free from engine, lower MTX to floor and slide it from under car.

Installation is essentially reverse of removal instructions.

Fill MTX with 2.25-2.5 qrts of MTX fluid via fill plug on side of mtx to the right of front trans mount

Fill Power Steering system

NOTE: DO NOT REMOVE SHIFT CABLES FROM SHIFT CABLE BRACKET, KEEP CABLES ON BRACKET

Save yourself the headache of trying to adjust shift cable ends by yourself, can be a real pain if you have never