Ford Workshop Service and Repair Manuals

Boot clamp tightening tool

204-169 (14-044)

1. 

   NOTE:Make sure the transmission is seated securely on the transmission jack.
   General note.
   • Place the transmission on the transmission jack and position it in the correct installation position under the car.
   • Renew all snap rings and self-locking nuts.
   • Fix the adapter plate onto the guide sleeves on the engine.

2. 

   CAUTION:Ensure that the two guide sleeves are installed.
   Locate the transmission up against the engine.

3. Do up the upper flange bolts.
   • Attach the cable guide.

4. 

   NOTE:Attach the CKP sensor cover.
   Do up the left-hand flange bolts.

5. Do up the right-hand flange bolts.

6. Fit the starter motor.
   1. Attach the retaining plate.
   2. Starter motor

7. Fit the starter motor.

8. Lower the vehicle.
   

   NOTE:Do not tighten the nuts.
   Raise the engine and fit the rear engine mounting.

9. Raise the vehicle.

10. 

    CAUTION:The inner joint must not be bent at more than 18 degrees; the outer joint must not be bent at more than 45 degrees.
    

    CAUTION:When installing the front driveshafts, use the locating sleeve (supplied with each new oil seal) to protect the oil seal.
    

    NOTE:Make sure the snap ring engages correctly.
    Install the right-hand front driveshaft with a new snap ring and the intermediate shaft in the transmission.

11. 

    CAUTION:The inner joint must not be bent at more than 18 degrees; the outer joint must not be bent at more than 45 degrees.
    Tighten the front drive halfshaft centre bearing.

12. 

    CAUTION:The inner joint must not be bent at more than 18 degrees; the outer joint must not be bent at more than 45 degrees.
    

    NOTE:Pack the tripode joint with new grease.For additional information, refer to Section  205-04 Front Drive Halfshafts.
    Install the left-hand front drive halfshaft together with tripode joint into the tripode housing.

13. Fill up with transmission fluid to 5-10 mm below the lower edge of the level check bore.

14. 

    CAUTION:The inner joint must not be bent at more than 18 degrees; the outer joint must not be bent at more than 45 degrees.
    

    NOTE:The intermediate shaft extension remains in the transmission.
    Insert the intermediate shaft into the intermediate shaft extension (shown with the intermediate shaft extension removed).
    1. Apply high-durability grease to the splines of the intermediate shaft and insert it into the intermediate shaft extension.
    2. Slide on the boot and clamping straps.

15. 

    CAUTION:The inner joint must not be bent at more than 18 degrees; the outer joint must not be bent at more than 45 degrees.
    Tighten the front drive halfshaft centre bearing.

16. 

    NOTE:Apply the special tool so that the clamp head is vertical to the clamping strap head.
    Tighten the clamping straps.

17. Tighten the clamping strap.

18. Top up transmission fluid (WSD-M2C200-C) to 5 - 10 mm below the lower edge of the fill hole.

19. Attach the left and right suspension arms (left-hand side shown).

20. Attach the exhaust pipe bracket and the exhaust pipe.

21. Fit the engine roll restrictor.

22. 

    NOTE:The coolant hose must be clipped into its retaining bracket.
    Attach the lower drive belt cover.

23. Attach the lower drive belt cover.

24. Connect the plug of the multi-function switch.

25. Lower the vehicle.

26. Tighten the rear engine mounting bracket.
    
    NOTE:The arrow on the transmission breather points towards the front of the vehicle.
    • Fit the transmission breather.

27. Remove the special tools.

28. Detach the rear engine lifting eye.

29. Tighten the nut on the exhaust flange.

30. Detach the front engine lifting eye.

31. Raise the vehicle.

32. 

    NOTE:Do not tighten the bolt on the selector shaft.
    Attach the selector shaft and the gearshift stabilizer to the transmission.
    
    NOTE:Washer
    1. Selector shaft stabilizer
    2. Selector shaft

33. 

    NOTE:Use a new gasket.
    Connect the exhaust system.
    • Remove the boot from the flexible pipe.

34. Remove the heat shield.

35. Adjust the gearshift mechanism.
    • Shift the transmission into fourth gear (from neutral, push the selector shaft forwards).
    • Lock the gearshift mechanism in fourth gear position with the shaft of a 9 mm drill bit in the gearshift housing.

36. Adjust the gearshift mechanism.

37. Tighten the selector shaft bolt.
    • Remove the twist drill bit from the selector mechanism.

38. Install the heat shield.

39. Lower the vehicle.

40. 

    NOTE:Renew the O-ring.
    

    NOTE:Make sure the spring clip engages securely.
    Fit the hydraulic pipe of the clutch operating mechanism.
    1. Insert the spring clip and connect the pipe to the pre-loading valve.
    2. Press the pipe into the guide.

41. Bleed the hydraulic clutch systemFor additional information, refer to Section  308-00 Manual Transmission/Transaxle and Clutch - General Information.

42. 

    WARNING:Escaping fuel.
    Connect the fuel feed and return pipe.For additional information, refer to Section  310-00 Fuel System - General Information.

43. Connect the VSS sensor plug.

44. Attach the speedometer drive cable.

45. Connect the transmission ground lead.

46. Connect the starter motor solenoid switch plug.
    1. Starter motor solenoid switch plug.
    2. Clip the wiring brackets in place.

47. Connect the HO2S plug.

48. Fit the battery box.

49. Install the battery.For additional information, refer to Section  414-01 Battery, Mounting and Cables.

50. Install the intake pipe.

51. Tighten the suspension strut nuts on the right and left.
    • Stop it from turning with an Allen key.
    • Tighten by hand with a ring spanner.
    • Use a torque wrench to tighten to specified torque.

52. Finishing operations.
    • Check the routing of cables and hoses and fix them in place with cable ties.
    • Enter the radio keycode.
    • Reprogram the preset radio stations.
    • Reset the clock.
    • Check the fluid levels and correct as necessary.
    • Carry out a road test to enable the PCM to gather data.