Lubricants, Fluids, Sealers and Adhesives | Item | Specification | | High-temperature grease | ESD-M1C220-A | | Sealer | WSK-M2G348-A5 | | Transmission fluid - manual transmission | WSD-M2C200-C | | Brake fluid (Super DOT 4) | ESD-M6C57-A | Capacities | | Litres | | Manual transmission fluid (0 - 5 mm below the lower edge of the level check bore) (from '983/4 MY) | 2,75 | | Manual transmission fluid (0 - 5 mm below the lower edge of the level check bore) (from '99 MY) | 1,9 | Transmission Ratios | | Gear set A | Gear set B1 | Gear set C | Gear set D | | 1st gear | 3,417 | 3,417 | 2,89 | 3,666 | | 2nd gear | 2,136 | 2,136 | 1,571 | 2,047 | | 3rd gear | 1,448 | 1,483 | 1 | 1,258 | | 4th gear | 1,028 | 1,114 | 0,698 | 0,864 | | 5th gear | 0,767 | 0,854 | - | 0,674 | | Reverse gear | 3,46 | 3,46 | 3,46 | 3,46 | Engine/Transmission Combinations | Engine | Gear set | Ratio | | 1.6 Zetec-E | A | 4,06 | | 1.6 Zetec-E | D | 3,84** | | 1.8 Zetec-E | A | 3,84 | | 1.8 Zetec-E | A | 3,41* | | 2.0 Zetec-E | A | 3,84 | | 2.0 Zetec-E | B1 | 3,84*** | | 2.5 Duratec-VE | A | 3,82 | | 2.5 Duratec-VE | A | 3,41* | | 2.5 Duratec-VE | B1 | 3,82**** | | 1.8 TCI-Diesel | D | 4,06 | * = France only ** = standard for France *** = standard for Italy, France and all sports versions in the UK **** = sports version Required Shim Thickness | Type | Input Shaft | Output Shaft | Differential | | Measuring shims (mm) | 1,00 | 1,00 | 1,10 | | Determined end float (mm) | + 0,22 | + 0,33 | + 0,36 | | Preload figure (mm) | -0.07 | + 0,13 | + 0,33 | | Required shim thickness (mm) | =1,17 | =1,46 | = 1,79 | | Shims available (mm) | 1,15 - 1,71 (in 0,01 mm steps) | 1,31 - 1,91 (in 0,02 mm steps) | 1,40 - 2,20 (in 0,05 mm steps) | Torque Specifications | Description | Nm | lb-ft | lb-in | | Flange bolts | 40 | 30 | | | Stud connections - starter motor/left-hand engine roll restrictor bracket | 20 | 15 | | | Right-hand driveshaft center bearing to bracket | 27 | 20 | | | Subframe to body | 130 | 96 | | | Steering gear to subframe | 130 | 96 | | | Radiator bracket to subframe | 10 | | 89 | | Rear engine mounting bracket to transmission | 83 | 61 | | | Air cleaner bracket to rear engine mounting | 23 | 17 | | | Front engine mounting bracket to engine and hydraulic bearing | 83 | 61 | | | Left-hand engine roll restrictor bracket to transmission (Zetec-E) | 48 | 35 | | | Left-hand engine roll restrictor bracket to transmission (1.8 TCI diesel) | 84 | 62 | | | Right-hand engine roll restrictor bracket to transmission | 84 | 62 | | | Center bolt of right and left-hand engine roll restrictor | 120 | 89 | | | Right-hand engine roll restrictor to subframe (Zetec-E) | 48 | 35 | | | Right-hand engine roll restrictor to subframe (1.8 TCI diesel) | 127 | 94 | | | Left-hand engine roll restrictor to subframe | 48 | 35 | | | Catalytic converter to exhaust | 41 | 30 | | | Power steering pipe bracket to subframe | 25 | 18 | | | Front wheel nuts | 85 | 63 | | | Hub nut | 340 | 251 | | | Lower suspension arm ball joint to spindle carrier | 83 | 61 | | | Track rod end to spindle carrier | 26 | 19 | | | Stabilizer bar connecting link to shock absorber | 47 | 35 | | | Power steering pipe to subframe (Zetec-E) | 9 | | 80 | | Power steering pipe to subframe (1,8 TCI Diesel) | 12 | 9 | | | Power steering pipe bracket to intake manifold | 10 | | 89 | | Air conditioning dehydrator to subframe | 7 | | 62 | | Bumper bracket to subframe | 9 | | 80 | | Transmission wiring harness bracket to transmission. | 12 | 9 | | | Suspension strut nut | 46 | 34 | | | Catalytic converter bracket to cylinder block | 24 | 18 | | | Clutch slave cylinder to transmission | 11 | 8 | | | Transmission-end housing section to clutch-end housing section | 32 | 24 | | | Reverse gear idler shaft mounting | 34 | 25 | | | Spur gear to differential | 88 | 65 | | | Selector finger to selector shaft | 28 | 21 | | | Selector gate to housing | 10 | | 89 | | Gearshift lever to selector shaft | 30 | 22 | | | Transmission fluid drain plug | 45 | 33 | | | Transmission fluid filler plug | 45 | 33 | | | Reversing lamp switch | 10 | | 89 | | Ball joint to selector lever shaft | 15 | 11 | | | Gearshift lever to gearshift lever shaft | 340 | 251 | | | Cover of internal selector mechanism | 10 | | 89 | | Reversing lamp actuating pin | 25 | 18 | | | Reverse gear idler shaft | 24 | 18 | | | Selector mechanism to transmission | 23 | 17 | | | |
