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308-06A Manual Transmission-Transaxle External Controls - Vehicles With: 5-Speed Manual Transmission (iB5) > < Transaxle

C-MAX 2003.75 (06.2003-)

Manual Transmission/Transaxle - Vehicles With: 6-Speed Manual Transmission (MMT6) - Transaxle—2.0L Duratorq-TDCi (DW) 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

303-290A-15
General Equipment
Transmission jack
Securing straps
Materials
Name
Specification
High-temperature grease
ESD-M1C220-A 
Grease
SA-M1C9107-A 

Installation

All vehicles
CAUTION:
CAUTION:Ensure that the two guide sleeves are installed.
  1. Raise the vehicle. For additional information, refer to:
    Anheben mit Hebebühne (100-02 Fahrzeug anheben, Description and Operation),
    Jacking (100-02 Jacking and Lifting, 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.

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

  1. Install the transmission lower bolts.
    • Install the wiring harness bracket.

  1. Install the rear engine mounting bracket.
    • Install the bolt on the rear engine mounting bracket.

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

  1. Install the rear engine mounting bracket bolts (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:
    Anheben mit Hebebühne (100-02 Fahrzeug anheben, Description and Operation),
    Jacking (100-02 Jacking and Lifting, Description and Operation).

  1. Remove the special tools.
  1. Lower the vehicle.

  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. Raise the vehicle. For additional information, refer to:
    Anheben mit Hebebühne (100-02 Fahrzeug anheben, Description and Operation),
    Jacking (100-02 Jacking and Lifting, Description and Operation).

  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. Install the radiator lower cover.

  1. Install the clutch pedal cover.
  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 catalytic converter bracket.

  1. NOTE:
    NOTE:Install new flexible pipe gasket and nuts.
    Attach the flexible pipe to the catalytic converter.
    • Coat the catalytic converter stud with grease before installing.

  1. Attach the catalytic converter clamp to the turbocharger.

  1. Remove the support sleeve or reinforcement from the flexible pipe.

  1. Attach the intercooler outlet pipe to the intercooler.
    • Install the hose clamps.
    • Install the bolts.

  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 cable ties from the lock panel.

  1. Install the transmission upper bolts.

  1. Attach the starter motor to the transmission.
    • Install the wiring harness bracket.

  1. Attach the ground lead to the transmission.

  1. Attach the gearshift cables to the transmission.
    1. Attach the gearshift cables to the abutment.
    1. Attach the gearshift and selector cables to the selector mechanism.
  1. Adjust the selector cable.
    For additional information, refer to: Gearshift Cable Adjustment - Vehicles With: 6-Speed Manual Transmission (MMT6) (308-00 Manual Transmission/Transaxle and Clutch - General Information, General Procedures).

  1. CAUTION:
    CAUTION:If brake fluid comes into contact with the paintwork, rinse off the affected areas with cold water without delay.
    Attach the clutch slave cylinder pipe 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 - Fahrzeuge ausgestattet mit MMT6/6-Gang Schaltgetriebe.

  1. Connect the reversing lamp electrical connector.

  1. Tighten the bolt of the rear engine mounting.
  1. Install the battery carrier.
    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. Install the air cleaner.
    For additional information, refer to: Air Cleaner - 2.0L Duratorq-TDCi (DW) Diesel (303-12 Intake Air Distribution and Filtering, Removal and Installation).
  1. Check the level of the transmission fluid.
    For additional information, refer to: Fill Procedure (308-03C Manual Transmission/Transaxle - Vehicles With: 6-Speed Manual Transmission (MMT6), General Procedures).
  1. Raise the vehicle. For additional information, refer to:
    Anheben mit Hebebühne (100-02 Fahrzeug anheben, Description and Operation),
    Jacking (100-02 Jacking and Lifting, Description and Operation).

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

  1. Fit the upper engine cover.
Vehicles with global closing
  1. Initialize window operating motor.
    For additional information, refer to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General Procedures).

308-06A Manual Transmission-Transaxle External Controls - Vehicles With: 5-Speed Manual Transmission (iB5) > < Transaxle