Ford XW4Z-5025-AA
Crossmember

The service and repair process for the front cross-member starts with separating the upper radiator sight shield followed by supporting the radiator to the upper radiator support. Begin by putting in the three-bar engine support before taking away both front wheel assemblies together with their attached tires. Remove first the two clips and set the front anti-lock brake sensors aside before uninstalling four bolts to position and support the front brake calipers. You should grasp the tie rod external hex while removing its two nuts for separation between tie rod ends and front spindles. To remove stabilizer bar links from the lower control arm, grasp their external hex portions and separate the links by removing and discarding the two nuts. The separation process starts with holding the ball joint external hex to remove and discard the nuts that separates the upper ball joint from the spindle. Unbolt the underbody splash shields while loosening the A/C and power steering line bracket nut above the front part of the radiator support crossmember by two turns before extracting the bolt to place the water control valve out of the way. In 3.9L vehicles you should take out the block heater harness retainer. First detach the power steering gear bolts before setting it aside for support. Next discard the engine mount nuts followed by disposal of the lower front strut mount bolts. Fasten the front crossmembers on the lift table while marking down the body positions of both crossmembers. To perform the installation, position the lifting table under both crossmembers then remove the assembly of engine crossmembers and radiator supports by taking out their total eight bolts. You must take off the control arm nuts along with bolts before removing them. The radiator support crossmember removal requires tooling and momentary removal of the bolts from the water control valve bracket along with bolt discarding before placing the stabilizer bar out of the way. First install new bolts to the stabilizer bar before placing the water control valve bracket into position while installing its accompanying bolts. Install the new control arm cam bolts and nuts in loose manner and put together the radiator support with engine crossmembers while checking the marked alignment and preventing engine weight from touching the crossmember before final bolt tightening. Begin by installing the four engine crossmember bolts before moving to the four radiator support crossmember bolts. Finally, install the engine mount nuts together with the new lower front strut mount bolts. Guiding the external hex of the ball joints allows correct spindle placement before new nuts are tightened. Position the lower control arms while gripping the external hex of stabilizer bar links and secure new nuts to install. Attach the power steering gear using its bolts and keep the external hex of the tie rods steady while guiding the two tie rod ends into the spindles and tightening new nuts. First install the front brake caliper bolts then position its two components before installing the front anti-lock brake sensors with their clips. All block heater harnesses should be installed into 3.9L vehicles. Place the water control valve properly before tightening its nut followed by installing bolts to the A/C and power steering brackets. Installation of underbody splash shields and front wheel and tire assemblies will complete the process while the three-bar engine support must be removed followed by separation of support from radiator before installing the upper radiator sight shield before front suspension alignment.

Position the two front brake calipers and install the bolts.

Position the two front I-braces and loosely install the four bolts, ensuring the four front I-brace insulators are correctly positioned before tightening the bolts.