Attachment III - Technical Information
SERVICE PROCEDURESThe following Service Procedure will replace both sub-frame rear retaining bolts, plate nuts and add or replace reinforcement plates under the mounts.
1. Remove the front floor mat.
2. Remove the push pin under the accelerator pedal which retains the carpet, if so equipped.
3. Pull back the front carpet to expose the front dash absorber.
4. On Continental models, proceed to Step 5. On Taurus/Sable models, proceed as follows:
^ Remove the push pin which holds the cowl side absorber in place.
^ Pull back dash absorber to expose the floor plan.
^ Locate the cowl side absorber push pin stud in the floor pan. Refer to Figure 1.
^ From the push pin stud, measure directly over 2 inches. Place a temporary mark at this location. Refer to Figure 1.
^ From the temporary mark, measure directly down 1 inch. See Figure 1. Center punch this new location.
^ Using a 2 1/2-inch hole saw, cut a hole in the floor pan at the center punched location. Do this same operation on the passenger side floor pan.
^ Proceed to Step 6.
5. On Taurus/Sable models, go back to Step 4. On Continental models, proceed as follows:
NOTE:
Cut out front dash absorber in one piece. The cut out section will be reinstalled during assembly.
^ Cut out front dash absorber in location and size shown in Figure 2. This will expose a circular stamped recess in the upper floor.
^ Measure 1 1/4 inches directly down from the lowest point of the circular stamped recess in the upper floor. See Figure 2. Center punch this new location.
NOTE:
Continentals have a double layer of sheet metal in the floor pan at this location. Using a 2 1/2-inch hole saw, cut a hole in the floor pan at the center punched location. Do this same operation on the passenger side floor pan. Refer to Figure 2.
^ Proceed to Step 6.
6. Look through the 2 1/2-inch hole. The sub-frame rear retaining bolt and plate nut should be easy to see. See Figure 3.
7. Spray rust penetrating lubricant on the sub-frame rear retaining bolt and plate nut. Do this on both sides.
CAUTION:
Front arms of hoist must be positioned as shown in illustration or possible vehicle damage could occur.
8. Raise and support the vehicle. Position the front arms of hoist on the sub-frame as shown in Figure 4.
9. Remove both of the sub-frame rear retaining bolts. Refer to Figure 4.
CAUTION:
Do not completely lower the vehicle as the sub-frame is being supported by the front arms of the hoist.
10. Partially lower the vehicle. Keep the weight of the vehicle on the hoist.
11. Using the 2 1/2-inch cut holes to gain access, straighten the plate nut retaining tabs and remove both plate nuts. See Figure 5.
12. Install new plate nuts. Bend the retaining tabs to secure the plate nuts in place.
13. Raise the vehicle.
14. Using hand tools, install the reinforcement plate and the new sub-frame rear retaining bolts as shown in Figure 6. Tighten the retaining bolts to 88-118 Nm (65-87 lb-ft).
15. Lower the vehicle.
16. Apply Super Seal or equivalent to the exposed metal of the access holes in the floor pan.
17. Install the supplied grommet to cover the access holes. See Figure 7.
18. Reposition the front dash absorber
19. Install the front dash absorber push pins.
20. Reposition the front carpet.
21. Reinstall the push pin under the accelerator pedal which retains the carpet, if so equipped.
22. Install both of the floor mats.