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In-vehicle Repair|Disassembly > < Transaxle - 1.6L Duratorq-TDCi (DV) Diesel

C-MAX 2003.75 (06.2003-)

Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75) - Transaxle—1.8L Duratorq-TDCi (Lynx) Diesel C-MAX 2003.75 (06/2003-)
Removal

Special Tool(s)

Support Bar, Engine

303-290A

Adapter for 303-290A

303-290-03A

Adapter for 303-290A

303-290-13

Adapters for 303-290A

303-290A-15, 303-290A-15/5, 303-290A-15/6, 303-290A-15/7
General Equipment
Transmission jack
Retaining straps

Removal

  1. Remove the air cleaner.
    For additional information, refer to: Air Cleaner - 1.8L Duratorq-TDCi (Lynx) Diesel (303-12 Intake Air Distribution and Filtering, Removal and Installation).
  1. Remove the battery carrier.
    For additional information, refer to: Batteriekonsole - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel (414-01, Removal and Installation).

  1. Detach the ground cables from the transmission.
    • Detach the pipe bracket from the transmission.

  1. Disconnect the reversing lamp switch connector.

  1. Detach the gearshift cables from the selector mechanism.
    1. Press the selector cable catch and detach the selector cable from the selector lever.
    1. Press the gearshift cable catch and detach the gearshift cable from the gear lever.

  1. Detach the gearshift cables from the abutment.
    1. Release the selector cable by turning the catch counter-clockwise and detach from the abutment.
    1. Release the gearshift cable by turning the catch counter-clockwise and detach from the abutment.

  1. WARNING:
    WARNING:If brake fluid comes into contact with the paintwork, the affected areas must be washed down immediately with cold water.
    WARNING:
    WARNING:Close off the clutch slave cylinder pipe to prevent fluid loss or dirt ingress.
    Detach the clutch slave cylinder pipe from the clutch slave cylinder.
    • Detach the clutch slave cylinder pipe from the bracket.
    • Remove the spring clip.

  1. Detach the turbocharger to intercooler air pipe from the transmission
    • Undo the hose clamp.
    • Unscrew the air pipe bracket nuts.

  1. Remove the turbocharger to intercooler air pipe.

  1. Detach the coolant pipe bracket from the transmission.

  1. Separate the discharge pipe from the intercooler discharge hose.
  1. Remove the headlamp assembly on both sides.
    For additional information, refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).

  1. Attach the special tool on both sides (right-hand side shown).
  1. Secure the radiator to the hood lock safety panel with cable ties.
  1. Raise the vehicle. For additional information, refer to: (100-02 Jacking and Lifting)
    Lifting (Description and Operation),
    Jacking (Description and Operation).

  1. Remove the engine undershield.

  1. Remove the radiator lower cover.

  1. Remove the crashbox.

  1. Remove the reinforcement brace (if equipped).

  1. WARNING:
    WARNING:Excessive bending of the flexible exhaust pipe can cause damage that may lead to component failure.
    Install a support sleeve or reinforcement on the flexible exhaust pipe.

  1. Remove and discard the exhaust manifold nuts.

  1. Detach the flexible exhaust pipe from the crossmember exhaust rubbers.

  1. WARNING:
    WARNING:The maximum permissible twisting angle of the flexible exhaust pipe is two degrees. Failure to follow this instruction may result in damage to the flexible exhaust pipe.
    NOTE:
    NOTE:Use a pry bar to prevent twisting of the flexible exhaust pipe while undoing the nuts.
    Disconnect the catalytic converter from the exhaust flexible pipe.
    • Discard the flexible exhaust pipe gasket and nuts.

  1. Remove the catalytic converter bracket.
    • Move the catalytic converter backwards.

  1. Remove the engine roll restrictor rubber mounting.
  1. Remove the halfshafts. For additional information, refer to: (205-04 Front Drive Halfshafts)
    Front Halfshaft RH (Removal and Installation),
    Front Halfshaft LH (Removal and Installation).

  1. Detach the coolant pipe bracket from the engine.
    • Disconnect the cable connector.
    • Unscrew and remove the nuts.

  1. Disconnect the crankshaft position sensor (CKP) electrical connector.

  1. Remove the right-hand transmission bolts.

  1. Detach the starter motor from the transmission.
    • Detach the ground cables from the transmission.
    • Secure the starter motor to one side.

  1. Remove the left-hand transmission bolt.

  1. Disconnect the glow plug relay connector.

  1. Remove the radiator support bracket bolts (left-hand side shown).

  1. Remove the radiator support bracket bolts (right-hand side shown).
    • Remove the radiator support bracket.

  1. Install the special tool.

  1. Install the special tool.

  1. Install the special tool.
    • Screw on the nut fingertight.

  1. NOTE:
    NOTE:Note the installation location of the special tool.
    Install the special tool.
  1. Lower the vehicle.

  1. Remove the transmission upper bolts.
    • Raise and secure the coolant pipe.

  1. Unscrew and discard the rear engine mounting bolt.
  1. Raise the vehicle. For additional information, refer to: (100-02 Jacking and Lifting)
    Lifting (Description and Operation),
    Jacking (Description and Operation).

  1. Lower the engine/transmission assembly using the special tool.

  1. Remove the rear engine mounting bracket (rear engine mounting shown removed for clarity).

  1. Remove the transmission lower bolts.

  1. Use suitable retaining straps to secure the transmission to the transmission jack.

  1. Remove the left-hand transmission bolts.
  1. Support the transmission using the transmission jack and remove.

In-vehicle Repair|Disassembly > < Transaxle - 1.6L Duratorq-TDCi (DV) Diesel