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308-03B Manual Transmission-Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75) > < Transaxle - 1.6L Zetec-SE (Sigma)-1.4L

Focus 1999 (08.1998-12.2004)

Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (iB5) - Transaxle—1.6L Zetec-E (Zetec)/1.8L Zetec-E (Zetec) Focus 1999 (08/1998-12/2004)
Installation

Special Tool(s)

Support Bar, Engine

303-290 (21-140)

Adapter for 300-290

303-290-01 (21-140-01)

Adapter for 303-290

303-290-02 (21-140-02)

Adapter for 303-290

303-290-03 (21-140-03)
General Equipment
Transmission jack
Tensioning strap
Materials
Name
Specification
Transmission fluid
WSD-M2C200-C

Installation

All vehicles
  1. General note.
    • Only use new self-locking nuts.

  1. CAUTION:
    CAUTION:Ensure that the two dowel pins are installed.
    Secure the transmission using the tensioning strap and bring into the installation position using the transmission jack .

  1. Tighten the flange bolts.

  1. Tighten the flange bolts.

  1. Install the starter motor and tighten the flange bolts.
    1. Starter motor bolt
    1. Flange bolt

  1. Install the engine support insulator.

  1. CAUTION:
    CAUTION:The inner joint must not be bent by more than 18 degrees. The outer joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Ensure that the halfshaft oil seal is not damaged.
    CAUTION:
    CAUTION:Ensure that the snap ring is correctly located in the groove.
    NOTE:
    NOTE:Install a new snap-ring.
    Attach the left-hand halfshaft to the transmission.
    • Remove the protective sleeve before fully installing the halfshaft.

  1. CAUTION:
    CAUTION:The inner joint must not be bent by more than 18 degrees. The outer joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Ensure that the halfshaft oil seal is not damaged.
    Attach the right-hand halfshaft to the transmission together with the intermediate shaft.
    • Remove the protective sleeve before fully installing the halfshaft.

  1. NOTE:
    NOTE:Use a new center bearing retaining bracket and new nuts.
    Install right-hand halfshaft centre bearing retaining bracket.

  1. CAUTION:
    CAUTION:Do not damage the boots.
    CAUTION:
    CAUTION:Ensure that the heat shield is installed to prevent heat damage to the ball joint.
    CAUTION:
    CAUTION:Renew lower suspension arm ball joint retaining nuts.
    Attach the lower suspension arm ball joints on both sides.

  1. Attach the gearshift and selector cables to the abutment.
    • Release the gearshift and selector cables by turning the catch clockwise and attach to the abutment.

  1. Attach the connector to the reversing light switch.
  1. Lower the vehicle.

  1. Using the special tool, raise the engine and transmission assembly far enough to install the rear engine mounting.

  1. Install the rear engine mounting bracket.

  1. CAUTION:
    CAUTION:Renew the rear engine mount nuts.
    Install the rear engine mounting.

  1. Remove the special tools.

  1. Tighten the upper flange bolts and starter motor bolts.
    1. Flange bolts
    1. Starter motor bolts
    • Attach the ground cable.

  1. WARNING:
    WARNING:Brake fluid will escape. Do not allow brake fluid to come into contact with the skin or eyes. If brake fluid should come into contact with your skin or eyes, rinse the affected area immediately with water.
    CAUTION:
    CAUTION:If brake fluid comes into contact with the paintwork, it should be washed off immediately with water.
    Connect the high-pressure pipe to the clutch slave cylinder.

  1. Insert the clutch hydraulic pipe into the retaining eye.
  1. Bleed the hydraulic clutch system. For additional information, refer to Section  308-00 Manual Transmission/Transaxle and Clutch - General Information.

  1. Attach the vehicle speed sensor (VSS) connector.

  1. Install the air cleaner.
    • Insert the air cleaner together with the intake hose and plenum chamber and screw in the bolts.

  1. Install the air cleaner.
    1. Attach the crankcase ventilation hose.
    1. Connect the mass air flow (MAF) sensor multiplug.

  1. Tighten the left-hand and right-hand suspension strut nuts.
    • Counterhold using an Allen key.
    • Tighten finger tight using a ring spanner.
    • Use a torque wrench to tighten to torque.
  1. Adjust the gearshift cables. For additional information, refer to Section  308-00 Manual Transmission/Transaxle and Clutch - General Information.

  1. With the vehicle on a level surface, fill the transmission with transmission fluid until the fluid level is just below the filler hole.

  1. Close the cover for the gearshift and selector cables.
  1. Connect the battery ground lead. For additional information, refer to Section  414-01 Battery, Mounting and Cables.
  1. Standard finishing operations.
    • Check the routing of the vacuum hoses and wiring and secure them with cable ties.
    • Check fluid levels again and correct if necessary.
Vehicles with front and rear power windows
  1. Initialize the window winder motors. For additional information, refer to Section  501-11 Glass, Frames and Mechanisms.

308-03B Manual Transmission-Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75) > < Transaxle - 1.6L Zetec-SE (Sigma)-1.4L