ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

ABOUT US
Transaxle - 2.5L > < Transaxle

Mondeo 1997 (08.1996-09.2000)

Automatic Transmission/Transaxle - Transaxle—1.6L/1.8L/2.0L Mondeo 1997 (08/1996-09/2000)
Installation

Special Tool(s)

Socket wrench, steering gear

211-186/202 (13-013)

Subframe locating pins

205-316 (15-097A)

Engine support bar

303-290 (21-140)

Adapter for 303-290

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

Adapter for 303-290k

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

Adapter for 303-290

303-290-03 (21-140-03)

Wrench, Intake Manifold

303-120 (21-066)

Alignment gauge, for powertrain

502-003 (21-172)
General Equipment
Transmission jack
Retaining strap
Steel straightedge
Materials
Name
Specification
High-temperature grease
ESD-M1C220-A 
Automatic transmission fluid
ESP-M2C166-H 

Installation

All Vehicles
  1. General note.
    • The torque converter hub must be engaged fully in the oil pump drive gear.
    • The locations of engine and transaxle mountings and engine support insulators are described looking from the transaxle to the engine.
    • All self-locking nuts must be renewed.
  1. CAUTION:
    CAUTION:The torque converter must remain at the correct installation depth throughout the whole installation procedure.
    NOTE:
    NOTE:The torque converter studs must be aligned with the engine drive plate holes before any transaxle retaining bolts are installed.
    Install the torque converter.

  1. CAUTION:
    CAUTION:The torque converter hub must be engaged fully in the oil pump drive gear.
    Check the installation depth of the torque converter.
    1. Lay a steel straightedge agross the automatic transaxle flange.
    1. Check the installation depth between the transaxle flange and the torque converter centering spigot for the correct clearance.
    • Apply a thin layer of high-temperature grease to the centering spigot bore on the torque converter.

  1. CAUTION:
    CAUTION:The torque converter must remain at the correct installation depth throughout the entire installation procedure. Check that the adapter plate is in the correct position.
    Using the transmission jack , install the transaxle.
    • Make sure the studs on the torque converter are entered into the engine drive plate and loosely install in the transaxle retaining flange bolts.

  1. Tighten the transaxle left-hand retaining bolts.

  1. Tighten the transaxle right-hand retaining bolts.

  1. NOTE:
    NOTE:Install new torque converter retaining nuts.
    Attach the torque converter to the engine drive plate (four nuts).
    • Install the rubber cover.

  1. Attach the vent pipe to the automatic transmission oil pan (if equipped).
  1. Lower the vehicle.
  1. Lift the engine and automatic transmission to installation height using the engine support bar.

  1. Loosen the center bolt on the rear engine mounting and align the rear engine mounting bracket without placing it under stress.

  1. NOTE:
    NOTE:Do not tighten the nuts at this stage.
    Install the rear engine mounting.
  1. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. CAUTION:
    CAUTION:Use an open ended spanner on the fluid line adapter to prevent it from turning.
    Attach the transaxle oil cooler line to the transaxle.

  1. Connect the turbine shaft speed (TSS) sensor electrical connector and clip the wiring harness in place.

  1. CAUTION:
    CAUTION:Use an open ended spanner on the fluid line adapter to prevent it from turning.
    Attach the transaxle oil cooler line to the transaxle.

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

  1. Detach the left-hand engine roll restrictor from the subframe.

  1. NOTE:
    NOTE:The gauge is marked with an arrow and "Front".
    Attach the gauge to the subframe.
    1. Attach the special tool.
    1. Install the bolts.
    1. Install the center bolt.

  1. NOTE:
    NOTE:Do not tighten the center bolt.
    Install the center bolt.

  1. Insert the two rubber guides of the lower radiator spigots into the subframe.

  1. NOTE:
    NOTE:Do not tighten the bolts.
    NOTE:
    NOTE:Align the steering gear and the fluid line bracket.
    NOTE:
    NOTE:Place a suitable piece of wood underneath the subframe.
    Lift the subframe into installation position using the transmission jack and attach it at the front.
    • Secure the radiator in the subframe (push fit)

  1. Using the special tool and install the steering gear (two bolts).

  1. NOTE:
    NOTE:Attach the bracket for the power steering fluid line and the bracket for the coolant line to the subframe.
    Using the special tool and install the steering gear heat shield.

  1. Align and attach the subframe.
    1. Insert the guide pins.
      2. NOTE:
      NOTE:The subframe must not move when the bolts are tightened.
    1. Tighten the bolts working diagonally.

  1. Attach the gauge to the automatic transmission bracket.
    • Tighten the center screw.
    • Lower the vehicle.

  1. CAUTION:
    CAUTION:Do not twist or strain the rear engine mounting.
    Tighten the nuts and the center bolt on the rear engine mounting bracket.
  1. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. NOTE:
    NOTE:Center the engine roll restrictor.
    Tighten the center bolt on the right-hand engine roll restrictor.

  1. Install the left-hand engine roll restrictor.
    • Remove the special tool.
      NOTE:
      NOTE:Center the engine roll restrictor.
    • Move the engine roll restrictor into installation position.
    1. Tighten the center bolt.
    1. Tighten the nuts.
    • Remove the guide pins.

  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.
    CAUTION:
    CAUTION:Make sure the snap ring is correctly seated.
    CAUTION:
    CAUTION:Make sure that the snap ring is fully engaged.
    Install the left-hand front driveshaft using a new snap-ring.
    • Remove the installation sleeve.

  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.
    CAUTION:
    CAUTION:Make sure that the snap ring is fully engaged.
    Attach the right-hand halfshaft and the intermediate shaft to the transaxle.
    • Attach the intermediate shaft bearing to the carrier.

  1. CAUTION:
    CAUTION:Protect the ball joint using a soft cloth to prevent damage.
    CAUTION:
    CAUTION:Do not damage the ABS sensor ring.
    Attach the lower suspension arms and stabilizer link rods.
Vehicles with air conditioning
  1. Attach the air conditioning dehydrator to the subframe.
All vehicles
  1. Install the right-hand vibration damper.
    1. Install the vibration damper
    1. Install the vibration damper bracket

  1. Attach the power steering fluid lines bracket to the subframe.

  1. Attach the transaxle fluid line to the bracket.

  1. Attach the struts to the subframe.

  1. Install the lower wheelhouse covers.

  1. CAUTION:
    CAUTION:Overstretching the flexible pipe can cause damage.
    Attach the exhaust pipe with a new gasket and hook it into the rubber loops.
  1. Lower the vehicle.

  1. Attach the steering shaft to the steeering linkage.

  1. Remove the special tools.

  1. Pre-tighten the nuts on both suspension struts.
    • Stop the assembly from turning

  1. Tighten the nuts on both suspension struts to torque.

  1. NOTE:
    NOTE:Ground lead bracket.
    Screw in the flange bolts.

  1. Attach the starter motor to the transaxle.

  1. Install the selector lever cable.
    1. Attach the selector lever cable to the selector lever.
    1. Attach the selector lever cable bracket to the transaxle.
  1. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.
  1. Remove the rear exhaust system heat shield.

  1. NOTE:
    NOTE:The selector lever has its own engagement system.
    Set the selector lever on the automatic transmission to the "D" (drive) position and check the adjustment of the selector lever cable.
    1. Hold the adjustment mechanism to stop it from moving.
    1. Undo the latch on the selector lever cable.
    1. The markings on the selector lever must line up.

  1. Lock the selector lever cable.
    1. Hold the adjustment mechanism to stop it from moving.
    1. Close the latch on the selector lever cable.
  1. Install the rear exhaust system heat shield.

  1. Install the lower radiator cover.

  1. Connect the OSS sensor electrical connector (if equipped).

  1. Install the engine undershield (nine bolts).
  1. Lower the vehicle.

  1. Connect the transaxle electrical connectors.
    1. Attach the ground cable to the transaxle case.
    1. Connect the automatic transaxle electrical connector.
    1. Connect the transmission range (TR) sensor electrical connector.
    1. Install the wiring harness retaining clip

  1. Remove the pins from the radiator support.

  1. Install the intake pipe and the air filter housing.
    1. Install the positive crankcase ventilation (PCV) hose.
    1. Install the intake hose.
    • Press the air cleaner housing into the rubber bushing.

  1. Install the intake pipe and the air intake housing.
    1. Connect the mass air flow (MAF) sensor electrical connector.
    1. Connect the intake air temperature (IAT) sensor electrical connector.
    1. Install the bolt and nuts.
  1. Connect the battery ground cable. For additional information, refer to Section  414-01 Battery, Mounting and Cables.
  1. Fill the transmission fluid.
    For additional information, refer to Transmission Fluid Drain and Refill in this section.

  1. Check the transaxle fluid.
    For additional information, refer to Fluid Level Check in this section.

Transaxle - 2.5L > < Transaxle