ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

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Transaxle - 1.8L Duratorq-TDCi (Lynx) Diesel > < Transaxle - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)

C-MAX 2003.75 (06.2003-)

Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75) - 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
Securing straps
Materials
Name
Specification
High-temperature grease
ESD-M1C220-A 
grease
SA-M1C9107-A 
Transmission fluid
WSD-M2C200-C 

Installation

CAUTION:
CAUTION:Ensure that the two guide sleeves are installed.
All vehicles
  1. Raise the vehicle. For additional information, refer to: (100-02 Fahrzeug anheben)
    Anheben mit Hebebühne (Description and Operation),
    Anheben mit Wagenheber (Description and Operation).
  1. Secure the transmission on the transmission jack using suitable retaining straps.
  1. Coat the input shaft splines with a thin coating of grease.

  1. Move the transmission into position using the transmission jack and install.
Vehicles built up to 02/2004
  1. NOTE:
    NOTE:Perform this and the following operation simultaneously.
    Install the left-hand transmission bolt.

  1. Install the right-hand transmission bolt.
    • Install the vacuum reservoir bracket (if equipped).
Vehicles built from 03/2004
  1. NOTE:
    NOTE:Perform this and the two following operations simultaneously.
    Screw in the lower transmission bolt.
    • Screw in the transmission bolt while pulling the transmission towards the engine at the same time.

  1. Install the left-hand transmission bolt.
    • Screw in the transmission bolt while pulling the transmission towards the engine at the same time.

  1. Install the right-hand transmission bolt.
    • Install the vacuum reservoir bracket (if equipped).
All vehicles
  1. Install the right-hand transmission bolt.
  1. Detach the retaining straps.
  1. Remove the transmission jack.

  1. Screw in the left-hand transmission bolt (catalytic converter shown removed for clarity).
Vehicles built up to 02/2004
  1. Install the transmission lower bolts.
    • Install the catalytic converter bracket.
Vehicles built from 03/2004
  1. Attach the catalytic converter bracket to the transmission.
    1. Install the transmission bolt.
    1. Tighten the transmission bolt.

  1. Screw in the catalytic converter bracket retaining bolt.
All vehicles
  1. Install the starter motor.
    For additional information, refer to: Anlasser - 1.6L Duratorq-TDCi (DV) Diesel (303-06 Anlasssystem, Removal and Installation).

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

  1. Tighten the clutch housing cover bolts.

  1. Raise the engine / transmission assembly slightly using the special tools.
  1. Lower the vehicle.

  1. Install the rear engine mounting bracket (rear engine mounting shown removed for clarity).

  1. NOTE:
    NOTE:Install a new bolt on the rear engine mounting.
    NOTE:
    NOTE:Do not tighten the bolt of the rear engine mounting for the moment.
    Install the bolt of the rear engine mounting.
  1. Raise the vehicle. For additional information, refer to: (100-02 Fahrzeug anheben)
    Anheben mit Hebebühne (Description and Operation),
    Anheben mit Wagenheber (Description and Operation).

  1. Remove the special tools.
  1. Install the left-hand halfshaft.
    For additional information, refer to: Linke Antriebswelle (205-04 Vorderradantriebswellen, Removal and Installation).
  1. Install the right-hand halfshaft.
    For additional information, refer to: Rechte Antriebswelle (205-04 Vorderradantriebswellen, Removal and Installation).

  1. Install the engine roll restrictors.

  1. Install the crashbox.
    1. Insert the M10 x 16 mm bolt.
    1. Insert the M10 x 25 mm bolts.
  1. Lower the vehicle.

  1. Remove the special tool on both sides (right-hand side shown).
  1. Install the headlamp assembly on both sides.
    For additional information, refer to: Scheinwerfereinheit (417-01 Außenbeleuchtung, Removal and Installation).

  1. Install the transmission upper bolts.

  1. Attach the ground lead to the transmission.

  1. CAUTION:
    CAUTION:If brake fluid comes into contact with the paintwork, rinse off the affected areas with cold water without delay.
    Connect the clutch slave cylinder line to the clutch slave cylinder.
    • Install the spring clip.
    • Attach the clutch slave cylinder pipe to the bracket.
  1. Bleed the clutch system.
    For additional information, refer to: Kupplungssystem entlüften (308-00 Schaltgetriebe und Kupplung - Allgemeine Informationen, General Procedures).

  1. Attach the gearshift cables to the abutment.
    1. Attach the gearshift cable to the abutment and secure by turning the catches clockwise.
    1. Attach the selector cable to the abutment and secure by turning the catches clockwise.

  1. Install the gearshift cables on the shift mechanism.
    1. Press the gearshift cable catch and attach the gearshift cable to the gear lever.
    1. Press the selector cable catch and attach the selector cable to the selector lever.
  1. Adjust the selector cable.
    For additional information, refer to: Schaltseilzug einstellen - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (MTX-75) (308-00 Schaltgetriebe und Kupplung - Allgemeine Informationen, General Procedures).

  1. Connect the reversing lamp electrical connector.
  1. Raise the vehicle. For additional information, refer to: (100-02 Fahrzeug anheben)
    Anheben mit Hebebühne (Description and Operation),
    Anheben mit Wagenheber (Description and Operation).
Vehicles built up to 02/2004
  1. Install the catalytic converter. For additional information, refer to: (309-00 Auspuffsystem - Allgemeine Informationen)
    Katalysator - 1.6L Duratorq-TDCi (DV) Diesel (Removal and Installation),
    Katalysator - 1.6L Duratorq-TDCi (DV) Diesel (110 PS), Abgasstufencode - VIN-Schild (Removal and Installation).
Vehicles built from 03/2004
  1. NOTE:
    NOTE:Install new flexible pipe gaskets and nuts.
    Attach the flexible pipe to the catalytic converter.
    • Coat the catalytic converter studs with grease before installing.

  1. Hook the flexible pipe into the crossmember rubber insulators.

  1. Remove the support sleeve or reinforcement from the flexible pipe.
All vehicles
  1. Install the radiator support bracket.
    • Install the radiator support bracket bolts (right-hand side shown).

  1. Install the radiator support bracket bolts (left-hand side shown).

  1. Connect the glow plug relay electrical connector.
  1. Lower the vehicle.

  1. Tighten the bolt of the rear engine mounting.
  1. Remove the cable ties from the lock panel.

  1. Connect the intercooler outlet pipe.
    • Screw on the nut.
  1. Raise the vehicle. For additional information, refer to: (100-02 Fahrzeug anheben)
    Anheben mit Hebebühne (Description and Operation),
    Anheben mit Wagenheber (Description and Operation).

  1. Install the intercooler outlet pipe.
  1. Install the battery carrier.
    For additional information, refer to: Batteriekonsole - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel (414-01 Batterie, Befestigung und Batteriekabel, Removal and Installation).
  1. Install the air cleaner.
    For additional information, refer to: Luftfilter - 1.6L Duratorq-TDCi (DV) Diesel (303-12, Removal and Installation).

  1. With the vehicle on a level surface, fill the transmission with transmission fluid until the fluid level is just below the filler hole.
  1. Raise the vehicle. For additional information, refer to: (100-02 Fahrzeug anheben)
    Anheben mit Hebebühne (Description and Operation),
    Anheben mit Wagenheber (Description and Operation).

  1. Install the engine undershield.
  1. Lower the vehicle.
Vehicles with global closing
  1. Initialize the power window motors.
    For additional information, refer to: Motor - elektrischer Fensterheber initialisieren (501-11 Fenster, Rahmen und Betätigungsmechanismen, General Procedures).

Transaxle - 1.8L Duratorq-TDCi (Lynx) Diesel > < Transaxle - 1.8L Duratec-HE (MI4)-2.0L Duratec-HE (MI4)