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In-vehicle Repair|Disassembly > < Selector Mechanism

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-)
Removal

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

Removal
  1. Remove the upper engine cover.
  1. Remove the air cleaner.
    For additional information, refer to: Air Cleaner - 1.8L Duratorq-TDCi (Lynx) Diesel (303-12 Intake Air Distribution and Filtering, Removal and Installation).
  1. Remove 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. CAUTION:
    CAUTION:If brake fluid comes into contact with the paintwork, rinse off the affected areas with cold water without delay.
    CAUTION:
    CAUTION:Close off the clutch slave cylinder pipe to prevent fluid loss or dirt ingress.
    Detach the clutch slave cylinder pipe from the clutch slave cylinder.
    • Detach the clutch slave cylinder pipe from the bracket.
    • Remove the spring clip.

  1. Disconnect the reversing lamp switch connector.

  1. Detach the gearshift cables from the transmission.
    1. Detach the gearshift and selector cables from the selector mechanism.
    1. Press the locking pins together and detach the gearshift cables from the abutment.

  1. Detach the ground lead from the transmission.

  1. Detach the starter motor from the transmission and secure it to one side.
    • Remove the wiring harness bracket.

  1. Remove the transmission upper bolts.
  1. Remove the headlamp assembly on both sides.
    For additional information, refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).

  1. Attach the special tool on both sides (right-hand side shown).
  1. Secure the radiator to the lock panel with cable ties.
  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 engine undershield.

  1. Detach the intercooler outlet pipe from the intercooler.
    • Remove the hose clamps.
    • Remove the bolts.

  1. Remove the crashbox.

  1. Install a support sleeve or reinforcement on the flexible pipe.

  1. Detach the catalytic converter clamp from the turbocharger.

  1. Detach the catalytic converter from the flexible pipe.
    • Discard the gasket and the retaining nuts for the flexible pipe.

  1. Remove the catalytic converter bracket.

  1. Remove the engine roll restrictors.
  1. Remove the right-hand halfshaft.
    For additional information, refer to: Front Halfshaft RH (205-04 Front Drive Halfshafts, Removal and Installation).
  1. Remove the left-hand halfshaft.
    For additional information, refer to: Front Halfshaft LH (205-04 Front Drive Halfshafts, Removal and Installation).

  1. Remove the radiator lower cover.

  1. Disconnect the glow plug relay connector.

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

  1. Remove the radiator support bracket bolts (right-hand side shown).
    • Remove the radiator support bracket.

  1. Remove the clutch housing cover.

  1. Install the special tools.

  1. Install the special tools.
  1. Lower the vehicle.

  1. Remove the bolt of the rear engine mounting.
    • Discard the bolt on the rear engine mounting.

  1. Unscrew and remove the rear engine mounting bracket bolts (rear engine mounting shown removed for clarity).
  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. Lower the engine/transmission assembly using the special tool.

  1. Remove the rear engine mounting bracket.
    • Remove the bolt from the rear engine mounting bracket.

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

  1. Secure the transmission on the transmission jack using suitable retaining straps.

  1. Remove the left-hand transmission bolt.
  1. Support the transmission using the transmission jack and remove.

In-vehicle Repair|Disassembly > < Selector Mechanism