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In-vehicle Repair|Disassembly > < Crankshaft Rear Seal

Transit 2000.5 (01.2000-05.2006)

Engine - 2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel - Engine—Vehicles With: Exhaust Gas Recirculation (EGR) Transit 2000.5 (01/2000-05/2006)
Removal

Special Tool(s)

Remover/Installer, Cooling Hose Clamp

303-397 (24-003)

Spacer, Subframe

204-606
General Equipment
Engine hoist
Trolley jack
Axle stands
Transmission jack

Removal

All vehicles
  1. WARNING:
    WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may ignite. Failure to follow these instructions may result in personal injury.
    Drain the cooling system.
    For additional information, refer to: Cooling System Draining, Filling and Bleeding (303-03 Engine Cooling, General Procedures).
  1. Remove the accessory drive belt.
    For additional information, refer to: Accessory Drive Belt - 2.4L Duratorq-Di (Puma) Diesel (303-05 Accessory Drive, Removal and Installation) /
    Accessory Drive Belt - 2.4L Duratorq-TDCi (Puma) Diesel (303-05 Accessory Drive, Removal and Installation).
  1. Remove the radiator grille opening panel.
    For additional information, refer to: Radiator Grille Opening Panel (501-02 Front End Body Panels, Removal and Installation).
  1. Remove the catalytic converter.
    For additional information, refer to: Catalytic Converter - 2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel/2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel (309-00 Exhaust System, Removal and Installation).

  1. NOTE:
    NOTE:Select neutral prior to removing the gearshift lever.
    Remove the gearshift lever.
    1. Pull up the boot.
    1. Pull the plunger and remove the gearshift lever.
    1. Remove the insulator.

  1. Remove the gearshift linkage insulation pad.

  1. Remove the stub lever.

  1. NOTE:
    NOTE:Make sure that the windshield wiper motor is in the park position.
    Remove the windshield wiper arms.

  1. Remove the cowl panel upper retaining screws.
    • Remove the screw covers.
  1. Raise the hood.

  1. Remove the hood seal.

  1. NOTE:
    NOTE:The windshield washer hose is routed through the cowl panel.
    Remove the cowl panel.
    1. Remove the lower retaining screws.
    1. Detach the windshield washer hose.
    1. Detach the clips.

  1. Remove the water drain pipe retaining clips.

  1. Remove the A-pillar exterior trim panel lower retaining screws.

  1. Remove the windshield wiper motor bracket retaining bolt.

  1. Remove the hood (four bolts).

  1. Remove the water drain panel.

  1. Using the special tool, disconnect the coolant hoses from the thermostat housing.

  1. Remove the radiator support bracket lower bolt.
Vehicles with air conditioning
  1. Disconnect the cooling fan motor electrical connector.
Vehicles with exhaust gas recirculation (EGR)
  1. Disconnect the EGR vacuum regulator solenoid vacuum lines.

  1. Disconnect the EGR vacuum regulator solenoid electrical connector.
All vehicles
  1. Using the special tool, disconnect the coolant expansion tank hose and the radiator lower hose.

  1. Disconnect the charge air cooler intake pipe from the turbocharger.
Vehicles with EGR
  1. Disconnect the charge air cooler outlet pipe from the EGR valve.
Vehicles without EGR
  1. Disconnect the charge air cooler outlet pipe from the intake manifold tube.
All vehicles
  1. Raise and support the vehicle.
    For additional information, refer to: Jacking (100-02 Jacking and Lifting, Description and Operation) /
    Lifting (100-02 Jacking and Lifting, Description and Operation).
4.25 tonne single chassis cab
  1. Remove the front bumper under-run.
All vehicles
  1. Turning the clutch slave cylinder counterclockwise, detach the clutch slave cylinder from the transmission.

  1. Disconnect the reversing lamp switch and the vehicle speed sensor (VSS) electrical connectors.
  1. Remove the exhaust hanger insulators and secure the exhaust to one side.
Vehicles built up to 10/2001
  1. NOTE:
    NOTE:Mark the position of the driveshaft flange in relation to the transmission output shaft flange.
    Detach the driveshaft from the transmission output shaft flange and position it to one side.
    • Discard the driveshaft flange retaining bolts.
Vehicles built 10/2001 onwards
  1. NOTE:
    NOTE:Mark the position of the driveshaft flange in relation to the transmission output shaft flange.
    Detach the driveshaft from the transmission output shaft flange and position it to one side.
    • Discard the driveshaft flange retaining bolts.
Vehicles with tachograph
  1. Disconnect the tachograph sensor electrical connector.
All vehicles
  1. Remove the transmission support insulator to front axle crossmember bolts.

  1. Disconnect the horn electrical connector.

  1. Remove the radiator support bracket right-hand retaining bolts.

  1. Remove the radiator support bracket and the radiator.

  1. Using a suitable transmission jack and wooden blocks support the front axle.

  1. Lower the front axle crossmember (left-hand side shown).
    • Remove the nuts and bolts.

  1. Install the special tool.
  1. Remove the transmission jack.
  1. Lower the vehicle.

  1. Disconnect the air cleaner outlet pipe from the turbocharger.

  1. Detach the power steering pump from the engine and position it to one side (four bolts).

  1. Disconnect the coolant hose from the water pump.

  1. Disconnect the engine wiring harness electrical connector.

  1. Remove the jump start point cover.

  1. Disconnect the battery to starter motor solenoid cable and the generator cable from the jump start point.

  1. Disconnect the fuel supply and return lines from the fuel filter.

  1. Disconnect the coolant hoses and the vacuum hoses from the heater core.

  1. Disconnect the engine ground cable from the side member.

  1. Disconnect the vacuum hose from the brake booster.
Vehicles with auxiliary heating
  1. Disconnect the auxiliary heater hoses.
All vehicles
  1. Using a suitable trolley jack, support the engine crossmember.

  1. Remove the engine crossmember retaining bolts.

  1. WARNING:
    WARNING:Make sure the engine rear lifting eye is removed after installation as it may come in contact with the brake pipe. Failure to follow this instruction may result in personal injury.
    Install the engine rear lifting eye.

  1. Remove the generator.

  1. Remove the power steering pump and generator mounting bracket.

  1. WARNING:
    WARNING:Always install a new engine front lifting eye. Failure to follow this instruction may result in personal injury.
    Install a new engine front lifting eye.

  1. Install the power steering pump and generator mounting bracket.
  1. Using a suitable trolley jack, support the transmission.
  1. Using a suitable engine hoist, with the aid of another technician, lower the engine and transmission assembly under the towing eye and pull the engine hoist with the engine and transmission assembly out of the engine compartment.
Vehicles with 135 PS diesel engine
  1. Remove the engine mount retaining nuts (right hand side shown).
Vehicles with 75 PS, 90 PS, 115 PS, 120 PS or 125 PS diesel engine
  1. Remove the vibration damper from the engine crossmember.

  1. Remove the engine crossmember.
All vehicles
  1. Remove the transmission right-hand retaining bolts.

  1. Remove the transmission left-hand retaining bolts.
  1. CAUTION:
    CAUTION:Do not tilt the transmission during removal. This may cause damage to the pilot bearing.
    Remove the transmission from the engine.

In-vehicle Repair|Disassembly > < Crankshaft Rear Seal