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Transaxle - 1.6L Duratorq-TDCi (DV) Diesel > < Transaxle

Assembly of Transaxle for 18L and 20L Duratec-HE Engines

Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75) - Transaxle—1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) 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

All vehicles
CAUTION:
CAUTION:Ensure that the two guide sleeves are installed.
  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 layer of grease.

  1. Move the transmission into position using the transmission jack and install.

  1. NOTE:
    NOTE:Perform this and the following operation simultaneously.
    Install the right-hand transmission bolt.

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

  1. Install the right-hand transmission bolts.

  1. Install the transmission lower bolts.

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

  1. Install the rear engine mounting bracket (the rear engine mounting is shown removed for a better view).

  1. NOTE:
    NOTE:Install a new bolt for 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. Attach the starter motor to the engine.

  1. Attach the wiring harness bracket to the engine.

  1. Attach the oil pressure switch connector.

  1. Fasten radiator support bracket on both sides (right side shown).
    • Push the radiator back into the installation position.
    • Screw in the rear bolt of the radiator support bracket.
    • Tighten the radiator support bracket bolts.

  1. Fasten the radiator support bracket on both sides (left side shown).
    • Screw in the rear bolt of the radiator support bracket.
    • Tighten the radiator support bracket bolts.
  1. Lower the vehicle.

  1. Remove the special tool on both sides (right-hand side shown).
  1. Remove the cable tie from the lock panel.
  1. Install the headlamp assembly on both sides.
    For additional information, refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
  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. NOTE:
    NOTE:Install a new gasket and nuts for the flexible pipe.
    Attach the flexible pipe to the catalytic converter.
    • Before installing, coat the catalytic converter stud bolts with grease.

  1. Attach the flexible pipe in the crossmember rubber insulators.

  1. Remove the support sleeve or reinforcement from the flexible pipe.
  1. Install the left-hand halfshaft.
    For additional information, refer to: Front Halfshaft LH (205-04 Front Drive Halfshafts, Removal and Installation).
  1. Install the right-hand halfshaft.
    For additional information, refer to: Front Halfshaft RH (205-04 Front Drive Halfshafts, Removal and Installation).

  1. Install the engine roll restrictors.

  1. Install the crashbox.
    1. Screw in the M10 x 16 bolt.
    1. Screw in the M10 x 25 bolts.
  1. Lower the vehicle.

  1. Install the transmission upper bolts.

  1. Attach the ground lead to the transmission.

  1. Tighten the bolt of the rear engine mounting.
  1. Install the cooling fan motor and shroud.
    For additional information, refer to: Motor – Elektrolüfter und Verkleidung (303-03C Kühlsystem - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), Removal and Installation).

  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.
    • Attach the clutch slave cylinder pipe to the bracket.
    • Install the spring clip.
  1. Bleed the clutch system.
    For additional information, refer to: Clutch System Bleeding (308-00 Manual Transmission/Transaxle and Clutch - General Information, 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 switch electrical connector.
  1. Install the battery tray.
    For additional information, refer to: Battery Tray - 1.6L Duratec-16V (Sigma)/1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (414-01 Battery, Mounting and Cables, Removal and Installation).
  1. Install the air cleaner.
    For additional information, refer to: Air Cleaner - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (303-12 Intake Air Distribution and Filtering, 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 window operating motor.
    For additional information, refer to: Motor - elektrischer Fensterheber initialisieren (501-11 Fenster, Rahmen und Betätigungsmechanismen, General Procedures).

Transaxle - 1.6L Duratorq-TDCi (DV) Diesel > < Transaxle