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Focus RS 2003 (09.2002-)

Manual Transmission/Transaxle - 2.0L Duratec-RS (Zetec) - Transaxle Focus RS 2003 (09/2002-)
Installation

Special Tool(s)

Support Bar, Engine

303-290 (21-140)

Adapter for 303-290

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
Securing straps
Materials
Name
Specification
Manual transmission fluid
WSD-M2C200-C 

Installation

  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.
  1. Using a suitable securing strap, secure the transaxle on a transmission jack.

  1. Using a suitable transmission jack, install the transaxle.

  1. Install the transaxle left-hand retaining bolts.
  1. Remove the securing strap.
  1. Remove the transmission jack.

  1. Install the transaxle right-hand retaining bolts.

  1. Attach the starter motor to the transaxle.

  1. Install the starter motor retaining bolts.

  1. Install the transaxle upper retaining bolts.

  1. Install the engine rear mount retaining bracket.
  1. Lower the vehicle.

  1. Using the special tools, raise the engine and transaxle assembly.

  1. NOTE:
    NOTE:Install a new engine rear mount center retaining nut.
    NOTE:
    NOTE:Do not tighten the engine rear mount retaining nuts at this stage.
    Install the engine rear mount.

  1. Remove the special tools.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Connect the vehicle speed sensor (VSS) electrical connector.

  1. CAUTION:
    CAUTION:Support the halfshaft. The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Do not damage the halfshaft oil seal.
    NOTE:
    NOTE:Install new intermediate shaft center bearing cap locknuts.
    Attach the right-hand halfshaft and the intermediate shaft to the transaxle.

  1. CAUTION:
    CAUTION:Support the halfshaft. The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Make sure the snap ring is correctly seated.
    CAUTION:
    CAUTION:Do not damage the halfshaft oil seal.
    NOTE:
    NOTE:Install a new snap ring.
    Attach the left-hand halfshaft to the transaxle.
  1. Install the subframe. For additional information, refer to Section  502-00 Uni-Body, Subframe and Mounting System.

  1. Install the engine support insulator.

  1. NOTE:
    NOTE:Install a new exhaust flexible pipe gasket and retaining nuts.
    Attach the exhaust flexible pipe to the muffler assembly.

  1. NOTE:
    NOTE:Install a new exhaust flexible pipe gasket and retaining nuts.
    Attach the exhaust flexible pipe to the catalytic converter.

  1. Connect the catalyst monitor sensor electrical connector.
    • Attach the catalyst monitor sensor wiring harness.

  1. Remove the exhaust flexible pipe support wrap.

  1. Attach the gearshift cables to the bracket and turn the abutment sleeves counterclockwise.
  1. Attach the gearshift cables to the selector levers.
  1. Lower the vehicle.

  1. Tighten the engine rear mount retaining nuts.

  1. CAUTION:
    CAUTION:If brake fluid is spilt on the paintwork, the affected area must be immediately washed down with cold water.
    Connect the clutch slave cylinder supply line to the transaxle.
    • Install the spring clip.

  1. Connect the reversing lamp switch electrical connector.

  1. Tighten the strut and spring assembly upper mount retaining nuts on both sides (left-hand side shown).

  1. Attach the ground cable to the body.

  1. Install the charge air cooler.
    • Attach the charge air cooler coolant hoses to the charge air cooler.
    • Connect the charge air cooler coolant temperature sensor connector.

  1. Attach the charge air cooler intake hose and outlet hose to the charge air cooler.
  1. Install the battery tray. For additional information, refer to Section  414-01 Battery, Mounting and Cables.
  1. Adjust the gearshift cables. For additional information, refer to Section  308-00 Manual Transmission/Transaxle and Clutch - General Information.
  1. Check the transaxle fluid level and top up with manual transmission fluid, if necessary.
    For additional information, refer to Fill Procedure in this section.
  1. Bleed the clutch system. For additional information, refer to Section  308-00 Manual Transmission/Transaxle and Clutch - General Information.

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