In-Vehicle Crossbeam

IN-VEHICLE CROSSBEAM

Exploded View

Taurus, Sable (Part 1):

Taurus, Sable (Part 2):

Taurus X (Part 1):

Taurus X (Part 2):

Removal
1. Remove the instrument panel upper section. Dashboard / Instrument Panel
2. Recover the A/C system. Service and Repair
3. Drain the cooling system. Service and Repair
4. Remove the wiper mounting arm and pivot shaft assembly. Wiper Arm
5. Remove the 2 nuts and the PCM.
- Disconnect the 3 PCM electrical connectors.







6. Remove the 3 nuts and the PCM bracket.







7. Remove the strut tower cross brace
- Remove the 2 LH and 2 RH strut upper mount nuts.







8. Remove the RH instrument panel upper cowl bolt.







9. Remove the 2 LH instrument panel upper cowl bolts.







10. Disconnect the vacuum hose and the evaporator purge solenoid hose from the upper intake manifold.







11. Remove the thermostatic expansion valve (TXV) manifold.
- Remove the TXV manifold bolt.
- Discard the O-ring seals.







12. Disconnect the heater hoses.







13. Remove the RH and LH front door weatherstrips.
14. Rotate the steering wheel to gain access to the steering column shaft-to-steering column bolt.
15. Remove and discard the steering column shaft-to-steering column bolt.







16. Rotate the steering wheel until the front wheels are in the straight-ahead position.
- Remove the ignition key.

17. CAUTION: Do not allow the steering column shaft to rotate while the intermediate shaft is disconnected or damage to the clockspring may result. If there is evidence that the shaft has rotated, the clockspring must be removed and recentered.

Detach the upper steering column shaft from the steering column.

18. Disconnect the LH side main wiring harness electrical connector.







19. Disconnect the 2 smart junction box (SJB) electrical connectors.







20. Remove the wire harness pin-type retainer from the SJB.
21. If equipped, disconnect the electrical connector located on the steering column opening bracket.







22. Disconnect the restraints control module (RCM) small electrical connector.







23. Disconnect the stability control sensor cluster electrical connector.







24. Remove the 4 instrument panel center support bolts.

25. CAUTION: To avoid damaging the in-vehicle crossbeam, an assistant is required when carrying out this step.

NOTE:
- Mark the location of the instrument panel side bolts for correct alignment upon installation.
- Remove the instrument panel side bolts from one side completely and support the in-vehicle crossbeam before removing the instrument panel side bolts from the opposite side.
- Make sure that all electrical connectors and wiring are not hindered before removing the in-vehicle crossbeam.

Remove the in-vehicle crossbeam.
- Remove the 6 instrument panel side bolts.
- Transfer parts as needed.

Installation

1. CAUTION: To avoid injury or damage to the in-vehicle crossbeam, the help of an assistant is required to carry out this step.

NOTE: Make sure that all electrical connectors and wiring are correctly routed when installing the in-vehicle crossbeam.

Position the in-vehicle crossbeam into the vehicle and install, but do not tighten, the following:
- Six instrument panel side bolts.
- Four instrument panel center support bolts.
- Three instrument panel upper cowl bolts.

2. NOTE: Align the instrument panel side bolts with the instrument panel side bolt markings.

Tighten the 6 instrument panel side bolts.
- Tighten to 40 Nm (30 lb-ft).

3. Tighten the 4 instrument panel center support bolts.
- Tighten to 25 Nm (18 lb-ft).

4. Tighten the 3 instrument panel upper cowl bolts.
- Tighten to 25 Nm (18 lb-ft).

5. Connect the stability control sensor cluster electrical connector.







6. Connect the small RCM electrical connector.







7. If equipped, connect the electrical connector located on the steering column opening bracket.







8. Connect the 2 SJB electrical connectors.







9. Install the wire harness pin-type retainer onto the SJB.
10. Connect the LH side main wiring harness electrical connector.







11. CAUTION: Do not allow the steering column shaft to rotate while the intermediate shaft is disconnected or damage to the clockspring may result. If there is evidence that the shaft has rotated, the clockspring must be removed and recentered.

Install the upper steering column shaft to the steering column.

12. Rotate the steering wheel to gain access to the steering column shaft-to-steering column bolt.
13. Install a new steering column shaft-to-steering column bolt.
- Tighten to 25 Nm (18 lb-ft).







14. Rotate the steering wheel until the front wheels are in the straight-ahead position.
15. Connect the heater hoses.







16. Install the TXV manifold and the TXV manifold bolt.
- Install new O-ring seals.
- Tighten to 8 Nm (71 lb-in).







17. Connect the vacuum hose and the evaporator purge solenoid hose to the upper intake manifold.







18. Install the strut tower cross brace.
- Install the LH and RH strut upper mount nuts
- Tighten to 30 Nm (22 lb-ft).







19. Install the PCM bracket and the 3 nuts.







20. Install the PCM and the 2 nuts.
- Connect the 3 PCM electrical connectors.







21. Install the wiper mounting arm and pivot shaft assembly. Wiper Arm
22. Charge the refrigerant. Service and Repair
23. Fill the cooling system. Service and Repair
24. Install the instrument panel upper section. Dashboard / Instrument Panel