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Ford Workshop Service and Repair Manuals

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Transaxle - 1.25L-1.4L Zetec-SE (Sigma)-1.6L > < Speedometer Driven Gear

Fiesta 1996 (08.1995-02.2002)

Manual Transmission/Transaxle - Transaxle—1.3L Endura-E (HCS) Fiesta 1996 (08/1995-02/2002)
Removal

Special Tool(s)

Extractor pin, drive shaft

16-087

Remover, front axle driveshaft

16-089

Engine support bar

21-140

Adapter for 21-140

21-140-01

Adapter for 21-140

21-140-03
Materials
Name
Specification
Transmission fluid
WSD-M2C200-C 

Removal

All Vehicles
  1. General note.
    • The position descriptions for the engine mountings and the engine roll restrictor are given looking from the transmission towards the engine.
  1. Preparatory operations
    • Make a note of the radio keycode.
    • Make a note of the preset radio stations.
  1. Disconnect the battery ground lead.

  1. NOTE:
    NOTE:Use an Allen key to stop the piston rod from turning.
    On each side loosen the suspension strut top nut five turns.

  1. Remove the air intake pipe.

  1. Remove the battery.
    • Disconnect the battery positive lead.
    • Remove the retaining clip.
    • Unclip the wiring brackets.

  1. Remove the battery box.

  1. Disconnect the plug of the heated exhaust gas oxygen sensor (HO2S).

  1. Disconnect the starter motor solenoid switch plug.
    1. Solenoid switch plug
    1. Unclip the wiring bracket.

  1. Disconnect the ground lead from the transmission.

  1. Disconnect the speedometer drive cable.

  1. Disconnect the vehicle speed sensor (VSS) connector.

  1. WARNING:
    WARNING:Escaping fuel.
    Detach the fuel supply and return hoses from the fuel rail. For additional information, refer to Section  310-00 Fuel System - General Information.
    • Mark the hoses.
    • Undo the quick-release couplings.

  1. NOTE:
    NOTE:Watch out for escaping brake fluid. Observe the safety precautions when dealing with brake fluid.
    Push the pipe out of the bracket.
    1. Pull out the securing clip and disconnect the pipe.
    1. Close off the openings with suitable plugs.

  1. Attach the engine lifting eyes.
    • Attach the engine lifting eye using the exhaust manifold nut (cylinder no. 4).
    • Engine lifting eye Finis Code: 6009618

  1. Attach the engine lifting eyes (continued).
      NOTE:
      NOTE:Enlarge the right-hand hole to a=10 mm.
    • Engine lifting eye Finis Code: 6630411

  1. Attach engine lifting eyes (continued).
    • Engine lifting eye Finis Code: 6630411

  1. Fit the special tools.

  1. Attach the special tools (continued)

  1. Remove the rear engine mounting (three nuts).
    • Pull out the transmission breather.
  1. Raise the vehicle.

  1. NOTE:
    NOTE:The drive belt cover must be removed as it would otherwise be destroyed when the engine is lowered.
    Remove the drive belt cover.

  1. Disconnect the plug of the multi-function switch.

  1. CAUTION:
    CAUTION:The flexible pipe can be damaged if it is bent too far.
    Support the flexible pipe with a suitable protective boot.

  1. Separate the exhaust system.

  1. Detach the shift rod and the gearshift stabilizer from the transmission.
    1. Shift rod
    1. Detach the gearshift stabilizer and tie it up.

  1. Remove the engine roll restrictor.

  1. Detach the exhaust pipe and exhaust pipe bracket.

  1. Detach the left and right suspension arms from the spindle carriers (left-hand side shown).

  1. CAUTION:
    CAUTION:The inner joint must not be bent at more than 18 degrees and the outer joint must not be bent at more than 45 degrees.
    NOTE:
    NOTE:Escaping oil. Close off the transmission with auxiliary plugs.
    Push the left-hand front driveshaft out of the transmission, pivot it backwards and tie it up.

  1. Release the front driveshaft centre bearing.
Vehicles with a two-part intermediate shaft
  1. CAUTION:
    CAUTION:The inner joint must not be bent at more than 18 degrees and the outer joint must not be bent at more than 45 degrees.
    Remove the right-hand front driveshaft from the transmission.
      CAUTION:
      CAUTION:After removing the front driveshaft, immediately prevent the differential turning with a suitable assembly stop.
    • Lightly tap the right-hand front driveshaft to release it from the transmission.
Vehicles with a one-part intermediate shaft
  1. CAUTION:
    CAUTION:The inner joint must not be bent at more than 18 degrees and the outer joint must not be bent at more than 45 degrees.
    CAUTION:
    CAUTION:After removing the front driveshaft, immediately prevent the differential turning with a suitable assembly stop.
    Pull the right-hand front axle driveshaft out of the transmission

  1. CAUTION:
    CAUTION:The inner joint must not be bent at more than 18 degrees and the outer joint must not be bent at more than 45 degrees.
    NOTE:
    NOTE:Do not damage the boots of the drive shaft.
    Tie up the right-hand front axle driveshaft towards the front.
  1. Lower the vehicle.

  1. NOTE:
    NOTE:Lower the transmission only until the transmission can be removed.
    Lower the transmission with the engine support bar to the level of the side member.
  1. Raise the vehicle.

  1. Disconnect the starter motor.

  1. Disconnect the starter motor (continued).
    1. Remove the retaining plate.
    1. Tie up the starter motor.

  1. Remove the flange bolts on the right-hand side.

  1. Remove the flange bolts at the top.
    • Place the cable guide to one side.
    • Remove the adapter plate.

  1. Remove the flange bolts at the left-hand side.
    • Lay the crankshaft position sensor (CKP sensor) cover to one side.

  1. NOTE:
    NOTE:Make sure the transmission is seated securely on the transmission jack.
    Separate the transmission from the engine and lower it.

Transaxle - 1.25L-1.4L Zetec-SE (Sigma)-1.6L > < Speedometer Driven Gear