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In-vehicle Repair|Disassembly > < Halfshaft Seal RH

Ford Focus RS 2003 Manual Transaxle Removal

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

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

Removal

  1. Remove the battery tray. For additional information, refer to Section  414-01 Battery, Mounting and Cables.

  1. Detach the charge air cooler intake hose and outlet hose from the charge air cooler.

  1. Remove the charge air cooler.
    • Detach the charge air cooler coolant hoses from the charge air cooler.
    • Disconnect the charge air cooler coolant temperature sensor connector.

  1. Detach the ground cable from the body.

  1. Disconnect the reversing lamp switch electrical connector from the transaxle.

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

  1. Loosen the strut and spring assembly upper mount retaining nuts by five turns on both sides (left-hand side shown).
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.
  1. Remove the right-hand wheel and tire. For additional information, refer to Section  204-04 Wheels and Tires.

  1. Detach the gearshift cables from the transaxle.
    1. Detach the gearshift cable (colored white) and the selector cable (colored black) from the selector levers.
    1. Turn the abutment collars clockwise and detach the cables from the bracket.

  1. CAUTION:
    CAUTION:Over bending of the exhaust flexible pipe may cause damage resulting in failure.
    Support the exhaust flexible pipe with a support wrap or suitable splint.

  1. Disconnect the catalyst monitor sensor electrical connector.
    • Detach the catalyst monitor sensor wiring harness.

  1. Detach the exhaust flexible pipe from the catalytic converter.
    1. Remove and discard the retaining nuts.
    1. Discard the gasket.

  1. Remove the exhaust flexible pipe.
    • Remove and discard the retaining nuts.
    • Discard the gasket.

  1. Remove the engine support insulator.
  1. Remove the subframe. For additional information, refer to Section  502-00 Uni-Body, Subframe and Mounting System.

  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:Plug the transaxle to prevent oil loss or dirt ingress.
    Detach the right-hand halfshaft and the intermediate shaft from the transaxle and secure it to one side.
    • Discard the center bearing cap and locknuts.
    • Allow the oil to drain into a suitable container.

  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 seals.
    NOTE:
    NOTE:Plug the transaxle to prevent oil loss or dirt ingress.
    Using a suitable drift, detach the left-hand halfshaft from the transaxle and secure it to one side.
    • Allow the oil to drain into a suitable container.
    • Remove and discard the snap ring.

  1. Disconnect the vehicle speed sensor (VSS) electrical connector.
  1. Lower the vehicle.

  1. Install the special tools.

  1. Remove the engine rear mount center retaining nut.
    • Discard the retaining nut.

  1. Remove the engine rear mount retaining nuts.

  1. Using the special tools, lower the engine and transaxle assembly.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Remove the engine rear mount retaining bracket.

  1. Remove the transaxle upper retaining bolts.

  1. NOTE:
    NOTE:Do not disconnect the starter motor electrical connector.
    Detach the starter motor from the transaxle and secure it to one side.

  1. Remove the starter motor retaining bolts.
    • Disconnect the ground cable from the transaxle.

  1. Remove the transaxle right-hand retaining bolts.

  1. Using a suitable securing strap, secure the transaxle to the transmission jack.

  1. Remove the transaxle left-hand retaining bolts.

  1. Using a suitable transmission jack, lower the transaxle.
  1. Remove the transaxle.

In-vehicle Repair|Disassembly > < Halfshaft Seal RH