Ford Workshop Service and Repair Manuals

Engine support bar

21-140

Adapter for 21-140

21-140-01

Adapter for 21-140

303-290-02 (21-140-02)

Adapter for 21-140

303-290-03 (21-140-03)

1. General note.
   • Renew all snap rings and self-locking nuts.

2. 

   CAUTION:Ensure that the two guide sleeves are installed.
   Move the transmission into position.

3. 

   NOTE:Throttle housing bracket
   Tighten the flange bolts (left-hand side).

4. Tighten the flange bolts (right-hand side).

5. Install the drive belt cover.

6. Lower the vehicle.

7. 

   NOTE:Do not tighten the nuts.
   Attach the rear engine mounting.
   
   NOTE:The arrow on the transmission breather points towards the front of the vehicle.
   • Fit the transmission breather.

8. Remove the special tool.

9. Detach the special tool.

10. Detach the special tool.

11. Tighten two upper flange bolts.
    • Connect the ground lead.

12. 

    NOTE:Renew the O-ring.
    Connect the hydraulic pipe of the clutch operating system.
    1. Fit the spring clip.
    
    NOTE:Make sure the spring clip engages securely.
    2. Press the line into the guide.

13. Raise the vehicle.

14. Attach the transmission ground cable.

15. Install the speedometer drive cable (if equipped).

16. Attach the bracket to the throttle body and screw in the starter motor flange bolt.

17. 

    CAUTION:The inner joint must not be bent at more than 18 degrees; the outer joint must not be bent at more than 45 degrees.
    

    CAUTION:When installing the intermediate shaft, use the locating sleeve (supplied with each new oil seal) to protect the oil seal.
    Install the right-hand front drive halfshaft and the intermediate shaft into the transmission.

18. 

    CAUTION:The inner joint must not be bent at more than 18 degrees; the outer joint must not be bent at more than 45 degrees.
    

    CAUTION:When inserting the front drive halfshafts always use the installation sleeve (supplied with every new oil seal) to protect the oil seal.
    

    NOTE:Make sure the snap ring engages correctly.
    Install the right-hand front drive halfshaft with a new snap ring and the intermediate shaft into the transmission.

19. 

    NOTE:Install a new retaining clip and new nuts.
    Install the front drive halfshaft intermediate bearing retaining clip.

20. 

    CAUTION:The inner joint must not be bent at more than 18 degrees; the outer joint must not be bent at more than 45 degrees.
    

    CAUTION:When inserting the front drive halfshafts always use the installation sleeve (supplied with every new oil seal) to protect the oil seal.
    

    NOTE:Make sure the snap ring engages correctly.
    Install the left-hand front drive halfshaft with a new snap ring into the transmission.

21. Top up transmission fluid (WSD-M2C200-C) to 5 - 10 mm below the lower edge of the fill hole.
    • Tighten the blanking plug.

22. Install the bracket/transmission shield.

23. Fit the engine roll restrictor.
    • Push the engine forwards.

24. Install the pipe of the power steering fluid cooler.
    1. Push on the A/C compressor electrical connector.
    2. Install the pipe of the power steering fluid cooler.
    3. Push on the connector of the power steering pressure switch.

25. Attach the right and left suspension arms to the spindle carriers (left-hand side shown).

26. Push the connector onto the multi-function switch (or reversing light switch if necessary) (multi-function switch connector shown).

27. Connect the exhaust pipe.
    • Remove the boot from the flexible pipe.

28. 

    NOTE:If it is not possible to install the shift stabilizer without it being under stress, align the engine/transmission so that it can be installed free of stress. Do not tighten the selector shaft clamp.
    Attach the gearshift stabilizer and the selector shaft to the transmission.
    
    NOTE:Washer
    1. Gearshift stabilizer
    2. Selector shaft

29. Adjust the gearshift mechanism.
    • Engage fourth gear (push the selector shaft from the neutral position up to the stop).
    • Lock the gear lever in fourth gear position using the shaft of a twist drill (9 mm diameter).

30. Adjust the gearshift mechanism.

31. Tighten the selector shaft bolt.
    • Remove the drill from the gearshift housing.

32. 

    NOTE:Multipart heat shield
    Install the heat shield.

33. 

    NOTE:Single part heat shield
    Install the heat shield.

34. Fit the radiator fan.
    1. Connect the plug.
    2. Slide the radiator fan upwards and insert it into the bracket.

35. Lower the vehicle.

36. Connect the plug of the vehicle speed sensor (VSS) (if equipped).

37. Tighten the rear engine mounting.

38. Bleed the hydraulic clutch systemFor additional information, refer to Section  308-00 Manual Transmission/Transaxle and Clutch - General Information.

39. Tighten the left-hand and right-hand suspension strut top nuts (right-hand side shown).
    • Stop it from turning with an Allen key.
    • Tighten by hand with a ring spanner.
    • Use a torque wrench to tighten to torque.

40. Install the intake pipe.

41. Attach the air intake pipe.

42. Fit the air intake pipe.
    • Install the ground lead on the battery tray .

43. Install the battery box.
    1. Attach the cable bracket.
    2. Tighten the bolts.

44. Finishing operations.
    • Check the fluid levels and correct as necessary.
    • Check the routing of vacuum hoses and wiring and secure with cable ties.
    • Install and connect the battery.
    • Enter the radio keycode.
    • Reprogram the preset radio stations.
    • Reset the clock.
    • Carry out a road test to enable the PCM to gather data.