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Manual Transaxle > < Transaxle - 1.4L Duratec-16V (Sigma)-1.6L Duratec-16V (Sigma)

Focus 2004.75 (07.2004-)

Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (iB5) - Transaxle—1.8L Duratec-HE (MI4) Focus 2004.75 (07/2004-)
Installation

Special Tool(s)

Support Bar, Engine

303-290A

Adapter for 303-290A

303-290-03A

Adapter for 303-290A

303-290-13

Adapter for 303-290A

303-290-15
General Equipment
Transmission jack
Retaining straps
Materials
Name
Specification
High-temperature grease
ESD-M1C220-A
Transmission fluid
WSD-M2C200-C

Installation

All vehicles
  1. Secure the transmission on the transmission jack using suitable retaining straps.

  1. CAUTION:
    CAUTION:Ensure that the two guide sleeves are installed.
    Move the transmission into position using the transmission jack and install.

  1. NOTE:
    NOTE:Perform this and the following operation simultaneously.
    Install the right-hand transmission bolt.

  1. Install the left-hand transmission bolt.
  1. Remove the retaining straps.
  1. Remove the transmission jack.

  1. Install the right-hand transmission bolts.

  1. Install the transmission lower bolts.

  1. Raise the engine / transmission assembly slightly using the special tools.
  1. Lower the vehicle.

  1. NOTE:
    NOTE:Install new rear engine mount retaining nuts.
    NOTE:
    NOTE:Do not tighten the rear engine mounting retaining nuts for the moment.
    Install the rear engine mount.

  1. CAUTION:
    CAUTION:If brake fluid comes into contact with the paintwork, rinse off the affected areas with cold water without delay.
    NOTE:
    NOTE:Make sure the spring clip is seated correctly.
    Connect the clutch slave cylinder line to the clutch slave cylinder.
    • Install the spring clip.
  1. Raise and support the vehicle.
    For additional information, refer to: Anheben mit Hebebühne (100-02 Fahrzeug anheben, Description and Operation).

  1. Remove the special tools.

  1. Remove the special tools.

  1. Remove the special tools.

  1. Remove the special tools on both sides (right-hand side shown).

  1. Attach the gearshift cables to the bracket and lock by turning the catch counter-clockwise.

  1. Attach the gearshift and selector cables to the selector mechanism.

  1. Install the gearshift cable cover.
  1. Install the right-hand halfshaft.
    For additional information, refer to: Rechte Antriebswelle (205-04 Vorderradantriebswellen, Removal and Installation).
  1. Install the left-hand halfshaft.
    For additional information, refer to: Front Halfshaft LH (205-04 Front Drive Halfshafts, Removal and Installation).

  1. Install the crashbox.
    1. Install the M10 x 16 bolt.
    1. Install the M10 x 25 bolt.

  1. Install the engine roll restrictors.

  1. NOTE:
    NOTE:Install new flexible pipe gaskets and nuts.
    Attach the flexible pipe to the catalytic converter.

  1. Attach the flexible pipe in the crossmember rubber insulators.

  1. Remove the support sleeve or suitable splints from the flexible pipe.

  1. Install the radiator support bracket.
    • Install the radiator support bracket left-hand retaining bolts.

  1. Install the radiator support bracket.
    • Install the radiator support bracket right-hand retaining bolts.

  1. Install the engine undershield.
  1. Lower the vehicle.

  1. Install the transmission upper bolts.

  1. Install the starter motor.
    • Connect the starter motor connector.

  1. Tighten the rear engine mount nuts.

  1. Attach the reversing lamp switch connector.
  1. Remove the cable ties from the radiator.
  1. Install the headlamp assembly on both sides.
    For additional information, refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
  1. Install the battery tray.
    For additional information, refer to: Battery Tray - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma)/1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (414-01 Battery, Mounting and Cables, Removal and Installation).
  1. Install the air cleaner.
    For additional information, refer to: Air Cleaner - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (303-12A Intake Air Distribution and Filtering, Removal and Installation).
  1. Adjust the gearshift cables.
    For additional information, refer to: Gearshift Cable Adjustment - Vehicles With: 5-Speed Manual Transmission (iB5) (308-00 Manual Transmission/Transaxle and Clutch - General Information, General Procedures).
  1. Bleed the clutch system.
    For additional information, refer to: Clutch System Bleeding (308-00 Manual Transmission/Transaxle and Clutch - General Information, General Procedures).
  1. With the vehicle on a level surface, fill the transmission with transmission fluid until the fluid level is just below the filler hole. Wait a few minutes until the fluid has distributed in the transmission and the fluid level has dropped, and then add more transmission fluid to the transmission until the level is exactly at the bottom edge of the filler hole.

  1. Install the engine cover.
Vehicles with global closing
  1. Initialize the window winder motors.
    For additional information, refer to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General Procedures).

Manual Transaxle > < Transaxle - 1.4L Duratec-16V (Sigma)-1.6L Duratec-16V (Sigma)