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Turbine Shaft Speed (TSS) Sensor > < Transaxle - 2.0L Duratorq-TDCi (Puma) Diesel

Mondeo 2001 (10.2000-02.2007)

Automatic Transmission/Transaxle - Vehicles With: 5-Speed Automatic Transmission (5F31J) - Transaxle—2.5L Duratec-VE (VE6) Mondeo 2001 (10/2000-02/2007)
Removal and Installation

Special Tool(s)

Support Bar, Engine

303-290A (21-140)

Adapter for 303-290A

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

Adapter for 303-290A

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

Adapter for 303-290A

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

Adapter for 303-290A

303-290-05A (21-140-05A)

Adapter for 303-290A

303-290A-14

Remover, Transmission Fluid Cooler

307-242 (17-049)

Remover, Halfshaft

308-256 (16-089)
General Equipment
Securing straps
Transmission jack
Worldwide diagnostic system (WDS)
Materials
Name
Specification
Grease
WSD-M1C230-A

Removal

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

  1. Remove the battery tray.

  1. Remove the engine upper cover.

  1. Remove the strut and spring assembly top mount brace cover on both sides.

  1. Loosen the strut and spring assembly top mount nuts by four turns on both sides.

  1. Remove the air cleaner.
    1. Disconnect the positive crankcase ventilation (PCV) hoses.
    1. Disconnect the mass air flow (MAF) sensor electrical connector.
    1. Disconnect the air cleaner intake hose.

  1. Disconnect the starter motor electrical connectors.

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

  1. Remove the selector lever cable cover.

  1. NOTE:
    NOTE:Make sure the transaxle selector lever is in "D" (DRIVE) position.
    Detach the selector lever cable from the selector shaft lever.
    1. Detach the selector lever cable from the selector shaft lever pin.
    1. Detach the selector lever cable from the selector lever cable bracket.
  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 seal.
    NOTE:
    NOTE:Cap the transaxle to prevent oil loss and dirt ingress.
    Detach the right-hand halfshaft and the intermediate shaft from the transaxle and secure it to one side.
    • Remove and discard the locknuts.
    • Discard the O-ring seal.

  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 seal.
    NOTE:
    NOTE:Cap the transaxle to prevent oil loss and dirt ingress.
    Using the special tool, detach the left-hand halfshaft from the transaxle and secure it to one side.
    • Discard the snap ring.
    • Discard the O-ring seal.

  1. Remove the torque converter retaining nuts.
    • Remove the cover.
    • Rotate the engine to gain access to the nuts.
    • Discard the nuts.
  1. Lower the vehicle.

  1. Disconnect the vent hose from the transaxle.

  1. Detach the ground cable from the transaxle.

  1. Remove the transaxle upper retaining bolts.

  1. Remove the bulkhead cover.

  1. Install the special tools.

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

  1. Remove the engine rear mount bracket.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.
Vehicles built up to 03/2003
  1. NOTE:
    NOTE:Cap the fluid cooler pipes to prevent oil loss and dirt ingress.
    Disconnect the fluid cooler pipes from the transaxle.
    • Allow the fluid to drain into a suitable container.
Vehicles built 03/2003 onwards
  1. NOTE:
    NOTE:NOTE: Cap the fluid cooler openings to prevent oil loss and dirt ingress.
    Using the special tool, disconnect the fluid cooler pipes.
    1. Insert the special tool into the quick release coupling.
    1. Slide the special tool along the pipe to release the locking tangs.
    • Allow the fluid to drain into a suitable container.
All vehicles
  1. Disconnect the transaxle electrical connectors.

  1. Remove the transaxle right-hand retaining bolts.

  1. Remove the transaxle left-hand retaining bolts.

  1. Remove the transaxle lower retaining bolts.

  1. WARNING:
    WARNING: Make sure the torque converter remains in the torque converter housing.
    NOTE:
    NOTE:Use a suitable wooden block to protect the transaxle.
    NOTE:
    NOTE:Secure the transaxle with securing straps.
    Using a suitable transmission jack remove the transaxle.
  1. NOTE:
    NOTE:Make a note of the position the dowel pins in the engine flange, to aid installation.
    Lower the transaxle.

Installation

All vehicles
  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 bolts are installed.
    Install the torque converter.

  1. CAUTION:
    CAUTION:The torque converter hub must engage fully in the oil pump drive gear.
    Check the installation depth of the torque converter.
    1. Lay a steel straight edge across the automatic transaxle flange.
    1. Check the installation depth between the steel straight edge and the drive plate stud.

  1. CAUTION:
    CAUTION:The torque converter must remain at the correct installation depth throughout the entire installation procedure.
    NOTE:
    NOTE:Secure the transaxle with securing straps.
    NOTE:
    NOTE:Use a suitable wooden block to protect the transaxle.
    NOTE:
    NOTE:Make sure that the dowel pins are correctly installed in the engine flange.
    Using a suitable transmission jack, install the transaxle.
  1. Remove the securing straps.

  1. Install the transaxle lower retaining bolts.

  1. Install the transaxle left-hand retaining bolts.

  1. Install the transaxle right-hand retaining bolts.

  1. Connect the transaxle electrical connectors.

  1. NOTE:
    NOTE:Install new torque converter retaining nuts.
    Install the torque converter retaining nuts.
    1. Rotate the engine to gain access to the nuts.
    1. Install the cover.
Vehicles built up to 03/2003
  1. Connect the fluid cooler pipes to the transaxle.
Vehicles built 03/2003 onwards
  1. Connect the fluid cooler pipes.
All vehicles
  1. Lower the vehicle.

  1. Install the engine rear mount bracket.

  1. NOTE:
    NOTE:Install a new engine rear mount center retaining nut.
    Install the engine rear mount.

  1. Remove the special tools.

  1. Install the bulkhead cover.

  1. Tighten the transaxle upper retaining bolts.

  1. Attach the ground cable to the transaxle.

  1. Connect the vent hose to the transaxle.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.
  1. Install a new left-hand halfshaft O-ring seal.
    • Lubricate the O-ring seal with grease.

  1. CAUTION:
    CAUTION: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 seal.
    CAUTION:
    CAUTION:Make sure the snap ring is correctly seated.
    NOTE:
    NOTE:Install a new snap ring.
    Attach the left-hand halfshaft to the transaxle.
  1. Install a new right-hand halfshaft O-ring seal.
    • Lubricate the O-ring seal with grease.

  1. CAUTION:
    CAUTION: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 seal.
    NOTE:
    NOTE:Install new locknuts.
    Attach the right-hand front drive halfshaft and the intermediate shaft to the transaxle.
  1. Install the subframe. For additional information, refer to Section  502-00 Uni-Body, Subframe and Mounting System.

  1. NOTE:
    NOTE:Make sure the transaxle selector lever is in the "D" (DRIVE) position.
    Connect the selector lever cable to the selector shaft lever.
    1. Attach the selector lever cable to the selector lever cable bracket.
    1. Attach the selector lever cable to the selector shaft lever pin.

  1. Open the yellow locking clip on the selector lever cable adjustment mechanism.
  1. Adjust the selector lever cable. For additional information, refer to Section  307-05A Automatic Transmission/Transaxle External Controls / 307-05B Automatic Transmission/Transaxle External Controls.
  1. Lower the vehicle.

  1. Install the starter motor.

  1. Connect the starter motor electrical connectors.

  1. Install the air cleaner.
    1. Connect the air cleaner intake hose.
    1. Connect the positive crankcase ventilation (PCV) hoses.
    1. Connect the mass air flow (MAF) sensor electrical connector.

  1. Tighten the strut and spring assembly top mount nuts on both sides.

  1. Install the strut and spring assembly top mount brace cover on both sides.

  1. Install the engine upper cover.

  1. Install the battery tray.
  1. Install the battery. For additional information, refer to Section  414-01 Battery, Mounting and Cables.
  1. CAUTION:
    CAUTION:If a new transaxle is being installed, a new transmission fluid oil cooler and new transmission fluid cooler tubes must be installed.
    Install a new transmission fluid cooler and new transmission fluid cooler tubes if necessary. For additional information, refer to Section  307-02A Transmission/Transaxle Cooling / 307-02B Transmission/Transaxle Cooling.
  1. Fill the transaxle.
    For additional information, refer to Transmission Fluid Drain and Refill in this section.
  1. NOTE:
    NOTE:Only carry out the following step when a new transaxle has been installed.
    Using worldwide diagnostic system (WDS), reset the transmission control module (TCM).
  1. Initialize the door window motors. For additional information, refer to Section  501-11 Glass, Frames and Mechanisms.

Turbine Shaft Speed (TSS) Sensor > < Transaxle - 2.0L Duratorq-TDCi (Puma) Diesel