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Manual Transmission > < Transaxle

Focus 2004.75 (07.2004-)

Manual Transmission/Transaxle - Vehicles With: 6-Speed Manual Transmission (MMT6) - Transaxle—2.0L Duratorq-TDCi (DW) Diesel Focus 2004.75 (07/2004-)
Installation

Special Tool(s)

Engine support bar

303-290A

Adapter for 303-290A

303-290-03A

Adapter for 303-290A

303-290-13

Adapter for 303-290A

303-290A-15
General Equipment
Transmission jack
Retaining straps
Materials
Name
Specification
High-temperature grease
ESD-M1C220-A 
grease
SA-M1C9107-A 
Transmission fluid
WSD-M2C200-C 

Installation

All Vehicles
CAUTION:
CAUTION:Ensure that the two guide sleeves are installed.
  1. Raise and support the vehicle.
    For additional information, refer to: Anheben mit Hebebühne (100-02 Fahrzeug anheben, Description and Operation) /
    Anheben mit Wagenheber (100-02 Fahrzeug anheben, Description and Operation).
  1. Use suitable retaining straps to secure the transaxle to the transmission jack.
  1. Coat the input shaft splines with a thin coating of grease.

  1. Move the transaxle into position using the transmission jack and install it.

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

  1. Install the transaxle lower retaining bolts.
    • Install the wiring harness bracket.

  1. Install the rear engine mounting bracket.
    • Install the bolts of the rear engine mounting.

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

  1. Install the bolts of the rear engine mounting (rear engine mounting shown removed for clarity).

  1. NOTE:
    NOTE: Install a new bolt on the rear engine mounting.
    NOTE:
    NOTE: Do not tighten the bolt of the rear engine mounting for the moment.
    Install the bolt of the rear engine mounting.
  1. Raise and support the vehicle.
    For additional information, refer to: Anheben mit Hebebühne (100-02 Fahrzeug anheben, Description and Operation) /
    Anheben mit Wagenheber (100-02 Fahrzeug anheben, Description and Operation).

  1. Remove the special tools.

  1. Remove the special tools.
  1. Lower the vehicle.

  1. Remove the special tool on both sides (right-hand side shown).
  1. Install the headlamp assembly on both sides.
    For additional information, refer to: Scheinwerfereinheit (417-01 Außenbeleuchtung, Removal and Installation).
  1. Raise and support the vehicle.
    For additional information, refer to: Anheben mit Hebebühne (100-02 Fahrzeug anheben, Description and Operation) /
    Anheben mit Wagenheber (100-02 Fahrzeug anheben, Description and Operation).

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

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

  1. Connect the glow plug relay electrical connector.

  1. Install the radiator lower cover.

  1. Install the clutch pedal cover.
  1. Install the left-hand halfshaft.
    For additional information, refer to: Linke Antriebswelle (205-04 Vorderradantriebswellen, Removal and Installation).
  1. Install the right-hand halfshaft.
    For additional information, refer to: Rechte Antriebswelle - 3-Türer (205-04 Vorderradantriebswellen, Removal and Installation).

  1. Install the engine roll restrictors.

  1. Install the catalytic converter bracket.

  1. NOTE:
    NOTE: Install a new gasket and new nuts.
    Attach the catalytic converter to the flexible pipe.
    • Coat the catalytic converter studs with grease before installing.

  1. Remove the support sleeve or reinforcement from the flexible exhaust pipe.

  1. Hook the flexible pipe into the crossmember rubber insulators.

  1. Attach the catalytic converter clamp to the turbocharger.

  1. Install the cross brace.

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

  1. Attach the intercooler outlet pipe to the intercooler.
    • Install the hose clamps.
    • Install the bolts.
  1. Lower the vehicle.
  1. Remove the cable ties from the radiator.

  1. Install the transmission upper bolts.

  1. Attach the starter motor to the transaxle.
    • Install the wiring harness bracket.

  1. Install the ground lead on the transaxle.

  1. Attach the gearshift cables at the transaxle.
    1. Attach the gearshift cables at the abutment.
    1. Attach the gearshift and selector cables at the selector mechanism.
  1. Adjust the selector cable.
    For additional information, refer to: Schaltseilzug einstellen - Fahrzeuge ausgestattet mit 6-Gang Schaltgetriebe (MMT6) (308-00 Schaltgetriebe und Kupplung - Allgemeine Informationen, General Procedures).

  1. CAUTION:
    CAUTION:If brake fluid comes into contact with the paintwork, rinse off the affected areas with cold water without delay.
    Attach the clutch slave cylinder pipe to the clutch slave cylinder.
    • Install the spring clip.
    • Attach the clutch slave cylinder pipe to the bracket.
  1. Bleed the clutch system.
    For additional information, refer to: Kupplungssystem entlüften - Fahrzeuge ausgestattet mit MMT6/6-Gang Schaltgetriebe.

  1. Connect the reversing lamp electrical connector.

  1. Tighten the bolt of the rear engine mounting.
  1. Install the battery carrier.
    For additional information, refer to: Batteriekonsole - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel (414-01 Batterie, Befestigung und Batteriekabel, Removal and Installation).
  1. Install the air cleaner.
    For additional information, refer to: Luftfilter - 2.0L Duratorq-TDCi (DW) Diesel (303-12 Ansaugsystem, Removal and Installation).

  1. With the vehicle on a level surface, fill the transaxle with transmission fluid until the fluid level is just below the filler hole.
  1. Raise and support the vehicle.
    For additional information, refer to: Anheben mit Hebebühne (100-02 Fahrzeug anheben, Description and Operation) /
    Anheben mit Wagenheber (100-02 Fahrzeug anheben, Description and Operation).

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

  1. Install the engine cover.
Vehicles with global closing
  1. Initialise the window regulator motors.
    For additional information, refer to: Motor - elektrischer Fensterheber initialisieren (501-11 Fenster, Rahmen und Betätigungsmechanismen, General Procedures).

Manual Transmission > < Transaxle