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Transaxle - 1.8L Duratec-HE (MI4) > < Transaxle - 1.8L Duratec-HE (MI4)

C-MAX 2003.75 (06.2003-)

Automatic Transmission/Transaxle - Vehicles With: Automatic Transmission (CFT23) - Transaxle—1.6L Duratorq-TDCi (DV) Diesel C-MAX 2003.75 (06/2003-)
Installation

Special Tool(s)

Support Bar, Engine

303-290A

Adapter for 303-290A

303-290-03A

Adapter for 303-290A

303-290-13

Adapter for 303-290A

303-290-15
General Equipment
Transmission jack
Tensioning strap

1. Install the components in the order indicated in the following illustration(s) and table(s).

 
Item
Part Number
Description
1
-
Transmission
See Installation Detail
2
-
Rear engine mount bracket
See Installation Detail
3
-
Rear engine mount
See Installation Detail

 
Item
Part Number
Description
4
-
Starter motor
See Installation Detail

 
Item
Part Number
Description
5
-
Left-hand front drive halfshaft
See Installation Detail
6
-
Right-hand front drive halfshaft
See Installation Detail
7
-
Engine roll restrictor
See Installation Detail
8
-
Exhaust pipe
See Installation Detail
9
-
Radiator support bracket
See Installation Detail
10
-
Charge air cooler outlet pipe
See Installation Detail

 
Item
Part Number
Description
11
-
Transmission upper bolts
See Installation Detail
12
-
Selector lever cable
See Installation Detail
13
-
Charge air cooler outlet pipe
See Installation Detail

  1. Install the lower radiator splash guard.

  1. Install the engine undershield.
  1. Lower the vehicle.

  1. Install the engine cover.

  1. Remove the special tools on both sides (right-hand side shown).
  1. Install the headlamp assembly on both sides.
    For additional information, refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
  1. Install the front wheels.
    For additional information, refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).
  1. Install the air cleaner.
    For additional information, refer to: Air Cleaner - 1.6L Duratorq-TDCi (DV) Diesel (303-12 Intake Air Distribution and Filtering, Removal and Installation).
  1. Adjust the selector lever cable.
    For additional information, refer to: Selector Lever Cable Adjustment (307-05B Automatic Transmission/Transaxle External Controls - Vehicles With: 4-Speed Automatic Transmission (4F27E), General Procedures).
  1. Fill the transmission with automatic transmission fluid.
    For additional information, refer to: Transmission Fluid Drain and Refill (307-01B Automatic Transmission/Transaxle - Vehicles With: 4-Speed Automatic Transmission (4F27E), General Procedures).
  1. Install the battery tray.
    For additional information, refer to: Battery Tray - 1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel (414-01 Battery, Mounting and Cables, Removal and Installation).
  1. Initialize the window winder motors.
    For additional information, refer to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General Procedures).

Installation Details

Item 1 : Transmission

  1. CAUTION:
    CAUTION:The torque converter must remain at the correct installation depth during the entire installation.
    CAUTION:
    CAUTION:Ensure that the two dowel pins are installed.
    CAUTION:
    CAUTION:Make certain that the transmission rests flat against the engine flange before any bolts are inserted or tightened.
    NOTE:
    NOTE:Before installing the bolts in the transmission, the torque converter studs must be aligned with the holes in the drive plate.
    Install the torque converter.

  1. CAUTION:
    CAUTION:The torque converter hub must engage fully with the oil pump drive gear.
    Check the installation depth of the torque converter.
    1. Position the steel straightedge on the transmission flange.
    1. Measure the correct installation depth between the automatic transmission flange and the torque converter guide collar.
  1. CAUTION:
    CAUTION:The torque converter must remain at the correct installation depth during the entire installation.
    NOTE:
    NOTE:Secure the transmission with the retaining straps.
    NOTE:
    NOTE:Support the transmission with suitable wooden blocks.
    NOTE:
    NOTE:The pins must be seated correctly in the engine flange.
    Move the transmission into position using the transmission jack and install.

  1. CAUTION:
    CAUTION:Perform this and the following operation simultaneously.
    Screw the lower bolt with the catalytic converter bracket into the transmission.

  1. Install the left-hand transmission bolts.

  1. Install the right-hand transmission bolt.
    • Install the vacuum reservoir bracket.

  1. Install the right-hand transmission bolt.
  1. Remove the retaining straps.
  1. Remove the transmission jack.

  1. Install the transmission lower bolts.
    • Attach the catalytic converter bracket to the transmission.
    • Install the catalytic converter bracket bolts.

  1. CAUTION:
    CAUTION:The automatic transmission contains components and assemblies which are sensitive to electrostatic charging.
    Attach the automatic transmission central connector.
    • Attach the central connector and lock by turning clockwise.

  1. Attach the transmission fluid cooler feed and return lines to the automatic transmission.

  1. Clip in the transmission fluid cooler feed and return lines at the fluid line bracket.

Item 2 : Rear engine mount bracket
  1. Install the engine rear mount bracket (engine rear mount shown removed for clarity).

Item 3 : Rear engine mount

  1. Lower the vehicle.

  1. NOTE:
    NOTE:Install a new rear engine mount retaining bolt.
    Install the engine rear mount retaining bolt.
  1. Raise the vehicle.

  1. Remove the special tools.

  1. Remove the special tools.

  1. Remove the special tools.

Item 4 : Starter motor
  1. Install the torque converter housing cover bolts.

  1. CAUTION:
    CAUTION:Ensure that the torque converter bolts do not fall into the torque converter housing.
    NOTE:
    NOTE:Replace the torque converter nuts.
    Install the torque converter nuts.
    • Turn the engine to gain access to the fastening points of the three nuts.
  1. Install the starter motor.
    For additional information, refer to: Starter Motor - 1.6L Duratorq-TDCi (DV) Diesel, Vehicles With: Automatic Transaxle (303-06 Starting System, Removal and Installation).

  1. Install the vacuum reservoir (shown with starter motor cable removed for clarity).
    • Tighten the vacuum reservoir bolt.
    • Connect the vacuum lines.

Item 5 : Left-hand front drive halfshaft

  1. Install the left-hand front drive halfshaft.
    For additional information, refer to: Front Halfshaft LH (205-04 Front Drive Halfshafts, Removal and Installation).

Item 6 : Right-hand front drive halfshaft

  1. Install the right-hand front drive halfshaft with intermediate shaft.
    For additional information, refer to: Front Halfshaft RH (205-04 Front Drive Halfshafts, Removal and Installation).

Item 7 : Engine roll restrictor
  1. Install the engine support insulator.

Item 8 : Exhaust pipe
  1. Screw in the catalytic converter bracket bolt.

  1. NOTE:
    NOTE:Install a new gasket and new nuts.
    Attach the catalytic converter to the flexible exhaust pipe.

  1. Detach the support sleeve or the reinforcement from the flexible exhaust pipe.

Item 9 : Radiator support bracket
  1. Tighten the right-hand radiator bracket bolts.

  1. Tighten the left-hand radiator bracket bolts.

Item 10 : Charge air cooler outlet pipe
  1. Attach the intercooler outlet pipe to the transmission.

Item 11 : Transmission upper bolts

  1. Lower the vehicle.

  1. Install the transmission upper bolts.
    • Attach the ground cable to the transmission.

Item 12 : Selector lever cable
  1. CAUTION:
    CAUTION:Do not kink the selector lever cable.
    Attach the selector lever cable to the transmission.
    1. Press the locking pins together and attach the selector lever cable to the abutment, press down the locking tab.
    1. Attach the selector lever cable to the selector mechanism.

Item 13 : Charge air cooler outlet pipe
  1. Connect the intercooler outlet pipe.

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