Measuring and adjusting shims | Description | Shim thickness | | Measuring shim | 3,8 mm | | Adjusting shim availability | 0,1 - 1,1 mm | Engine and transmission combinations | Engine | | Gear set | Differential ratio | | 1,3 Endura E | Saloon | A | 3,82 | | 1,3 Endura E | Saloon | B* | 3,82 | | 1,3 Endura E | Courier | A | 4,06 | | 1,25 Zetec SE | Saloon | B | 4,25 | | 1,4 Zetec SE | Saloon | A | 4,25 | | 1,4 Zetec SE | Courier | A | 4,25 | | 1,8 Endura DE | Saloon | B | 3,82 | | 1,8 Endura DE | Courier | B | 3,82 | | * = For France only | Transmission ratios | | Gear set A | Gear set B | | First gear | 3,58 | 3,58 | | Second gear | 2,04 | 1,93 | | Third gear | 1,32 | 1,28 | | Fourth gear | 0,95 | 0,95 | | Fifth gear | 0,76 | 0,76 | | Reverse gear | 3,62 | 3,62 | | Speedometer drive pinion | 20 | 20 | | Speedometer drive worm wheel | 21 | 21 | Clutch | | Endura-E/Zetec-SE | Endura-DE | | Diameter | 180 mm | 210 mm | | Type | Single-plate dry clutch | | Operation | Hydraulic | | Pedal travel (adjustable, up to build month 09/1998) | 125 ± 3 mm | Lubricants, Fluids, Sealers and Adhesives | Item | Specification | | Transmission fluid (SAE 75W90) | WSD-M2C200-C | | High temperature grease | ESDM-1C220-A | | Brake fluid (DOT 4) | SAM-6C9103-A | | Liquid sealer, transmission housing | WSK-M2G348-A5 | | Liquid sealer, end cover | WSE-M4G323-A4 | Capacities | | Litres | | Transmission fluid | 2,8 | | Filling level | 5 - 10 mm below lower edge of check bore | Measuring and adjusting shims (differential, measurements in mm) | | Shim thickness | | Measuring shim | 3,8 | | Adjusting shim availability (in increments of 0,1 mm) | 0,1 - 1,1 | Torque Specifications | Description | Nm | lb-ft | lb-in | | Transmission - remove and install | | | - | | Flange bolts - transmission to engine | 44 | 32 | - | | Resonator (bolt) | 33 | 24 | - | | Resonator (nut) | 32 | 24 | - | | Engine mounting to transmission | 70 | 52 | - | | Engine mounting to engine | 69 | 51 | - | | Engine roll restrictor to engine | 50 | 37 | - | | Engine roll restrictor to front axle | 70 | 52 | - | | Center bearing - right-hand axle driveshaft | 24 | 18 | - | | Lower suspension arm to spindle carrier | 52 | 38 | - | | Track rod to spindle carrier | 36 | 27 | - | | Stabiliser bar link rod to suspension strut | 47 | 35 | - | | Front exhaust pipe to catalytic converter | 47 | 35 | - | | Exhaust manifold to catalytic converter, stage 1 | 25 | 18 | - | | Exhaust manifold to catalytic converter - wait 10 seconds- stage 2 | 40 | 30 | - | | Exhaust flange to engine | 23 | 17 | - | | Stabiliser to transmission | 55 | 41 | - | | Shift rod to transmission | 23 | 17 | - | | Gearshift mechanism to body | 24 | 18 | - | | Wheel nuts | 85 | 63 | - | | Suspension strut nut | 45 | 33 | - | | Driveshaft stub nut | 270 | 199 | - | | Starter motor to transmission | 44 | 32 | - | | Clutch to flywheel | 30 | 22 | - | | Battery box | 25 | 18 | - | | Transmission - dismantle and assemble | | | | | Transmission end transmission housing section to clutch end transmission housing section (bolts) | 22 | 16 | - | | Transmission end transmission housing section to clutch end transmission housing section (studs) | 33 | 24 | - | | Crown wheel to differential (8-hole) | 83 | 61 | - | | Crown wheel to differential (6-hole) | 113 | 83 | - | | Selector block to main selector shaft | 14 | 10 | - | | Mounting block to clutch housing | 22 | 16 | - | | Gate to clutch housing | 26 | 19 | - | | Fifth gear housing to transmission housing | 13 | 10 | - | | End cover | 12 | 9 | - | | Selector finger to fifth gear selector shaft | 17 | 13 | - | | Selector shaft detent mechanism | 23 | 21 | - | | Transmission fluid drain plug | 35 | 26 | - | | Multi-function switch | 6,5 | 4 | 58 | | Pre-load valve | 10 | 7 | 89 | | Clutch Slave Cylinder | 10 | 7 | 89 | | Bleed nipple | 14 | 10 | - | | |
