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307-02 Transmission-Transaxle Cooling - Vehicles With: 4-Speed Automatic Transmission (AW81-40) > < Vehicle Speed Sensor (VSS)

Fiesta 2002.25 (11.2001-)

Automatic Transmission/Transaxle - Vehicles With: 4-Speed Automatic Transmission (AW81-40) - Transaxle Fiesta 2002.25 (11/2001-)
Removal and Installation

Special Tool(s)

Protector, Halfshaft Seal

205-775

Separator, Ball Joint

211-020 (13-006)

Support Bar, Engine

303-290A

Adapter for 303-290A

303-290-01 (21-140-01)

Adapter for 303-290A

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

Adapter for 303-290A

303-290A-14
General Equipment
Securing strap
Transmission jack
Worldwide diagnostic system (WDS)
Materials
Name
Specification
Grease
WSD-M1C230-A 

Removal

WARNING:
WARNING:Refer to the Material Safety Data Sheets for the Automatic Transmission Fluid E-AW. Failure to follow this instruction may result in personal injury. Certain Transmission and Power Steering fluids supplied to Ford contain additives which may cause skin irritation or other skin reactions after contact.
For additional information, refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
See - Transmission Fluids.
  1. Remove the air cleaner.
    For additional information, refer to: Air Cleaner - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) (303-12 Intake Air Distribution and Filtering, Removal and Installation).
  1. Disconnect the powertrain control module (PCM) electrical connector.
    For additional information, refer to: Powertrain Control Module (PCM) - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) (303-14 Electronic Engine Controls, Removal and Installation).
  1. Remove the battery tray.
    For additional information, refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation).

  1. Loosen the strut and spring assembly top mount nuts by three turns on both sides.

  1. Detach the engine ground cable from the transaxle.

  1. Remove the transaxle upper retaining bolts.
    • Detach the engine wiring harness bracket from the transaxle.

  1. Detach the ground cable from the transaxle.

  1. Disconnect the turbine shaft speed (TSS) sensor electrical connector.

  1. Disconnect the transaxle breather hose.

  1. Disconnect the transaxle wiring harness electrical connector.

  1. Disconnect the transmission range (TR) sensor electrical connector.

  1. Disconnect the vehicle speed sensor (VSS) electrical connector.
  1. Remove the front wheels and tires.
    For additional information, refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).

  1. Detach the selector lever cable from the manual shift lever.

  1. Detach the selector lever cable retaining bracket from the transaxle and position it to one side.

  1. Remove the transmission fluid level indicator tube.

  1. Disconnect the ignition switch to starter motor solenoid and battery to starter motor solenoid cables.

  1. Remove the accessory drive belt cover.

  1. Remove the engine support insulator.

  1. CAUTION:
    CAUTION:Over bending of the exhaust flexible pipe may cause damage resulting in failure.
    Support the exhaust flexible pipe with a suitable support wrap or suitable splint.

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

  1. CAUTION:
    CAUTION:Leave the tie-rod end retaining nut in place to protect the ball joint stud.
    NOTE:
    NOTE:Use a 5mm Allen key to prevent the ball joint stud from rotating.
    Loosen the right-hand tie-rod end retaining nut.

  1. CAUTION:
    CAUTION:Protect the ball joint seal using a soft cloth to prevent damage.
    Using the special tool, detach the right-hand tie-rod end from the wheel knuckle.
    1. Release the tie-rod end.
    1. Remove and discard the tie-rod end retaining nut.

  1. CAUTION:
    CAUTION:Protect the ball joint seal.
    Detach the lower arm from the wheel knuckle on both sides.
    • Remove the heat shield.

  1. CAUTION:
    CAUTION:Support the halfshaft. The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Do not damage the halfshaft seal.
    NOTE:
    NOTE:Plug the transaxle to prevent oil loss or dirt ingress.
    For additional information, refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
    See - Transmission Fluids.
    Using a suitable tire lever, detach the left-hand halfshaft from the transaxle and secure it to one side.
    • Allow the oil to drain into a suitable container.
      For additional information, refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
      See - Transmission Fluids.
    • Discard the snap ring.

  1. CAUTION:
    CAUTION:Support the halfshaft. The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Do not damage the halfshaft seal.
    NOTE:
    NOTE:Plug the transaxle to prevent oil loss or dirt ingress.
    For additional information, refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
    See - Transmission Fluids.
    Detach the right-hand halfshaft and the intermediate shaft from the transaxle and secure it to one side.
    • Discard the center bearing cap and locknuts.
    • Allow the oil to drain into a suitable container.
      For additional information, refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
      See - Transmission Fluids.
  1. Lower the vehicle.

  1. Remove the battery tray support bracket.

  1. WARNING:
    WARNING:When releasing the transmission fluid, take care to prevent scolding. Failure to follow this instruction may result in personal injury.
    CAUTION:
    CAUTION:Plug the transmission fluid cooler feed and return lines to prevent fluid loss or dirt ingress.
    For additional information, refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
    See - Transmission Fluids.
    NOTE:
    NOTE:Mark the position of the feed and return lines to aid installation.
    Detach the transmission fluid cooler lines from the transmission.
    1. Push the transmission fluid cooler line quick release connector onto the transmission.
    1. Press together the retaining tabs and detach the transmission fluid cooler line from the transmission.
    • Allow the fluid to drain into a suitable container.
      For additional information, refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
      See - Transmission Fluids.

  1. Install the special tools.

  1. Remove the engine and transaxle rear mount.
    • Discard the nuts.

  1. Using the special tools, lower the engine and transaxle assembly.

  1. Remove the engine and transaxle rear mount retaining bracket.
  1. Raise and support the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. Remove the starter motor.

  1. Remove the torque converter retaining nuts.
    • Rotate the torque converter to gain access to the nuts.
    • Discard the nuts.

  1. Remove the transaxle lower retaining bolts.

  1. NOTE:
    NOTE:Secure the transaxle with a securing strap to the transmission jack.
    Using a suitable transmission jack, support the transaxle.

  1. Tilt the engine and transaxle assembly forwards and insert a suitable wooden block.

  1. Remove the transaxle right-hand retaining bolts.
  1. CAUTION:
    CAUTION:Make sure the torque converter remains in the transaxle.
    Using the transmission jack and remove the transaxle.

Installation

  1. CAUTION:
    CAUTION:The torque converter must remain at the correct installation depth during the entire installation.
    NOTE:
    NOTE:Before installing the bolts in the transmission, the torque converter studs must be aligned with the holes in the drive plate.
    Install the torque converter.
    • Lubricate the torque converter centering spigot with grease.

  1. CAUTION:
    CAUTION:The torque converter hub must engage fully with the oil pump drive gear.
    Check the installation depth of the torque converter.
    1. Lay a straight edge on the transaxle flange.
    1. Check the installation depth between the transaxle flange and the torque converter centering spigot.

  1. CAUTION:
    CAUTION:The torque converter must remain at the correct installation depth during the entire installation.
    NOTE:
    NOTE:Secure the transmission with the securing strap.
    NOTE:
    NOTE:Make sure that the two locating dowels are installed.
    Using a suitable transmission jack, install the transaxle.

  1. Install the transaxle right-hand retaining bolts.
  1. Remove the wooden block.
  1. Remove the securing strap.
  1. Remove the transmission jack.

  1. Install the transaxle lower retaining bolts.

  1. NOTE:
    NOTE:Install new torque converter retaining nuts.
    Install the torque converter retaining nuts.
    1. Rotate the torque converter to gain access to the nut bolts.

  1. Install the starter motor.
  1. Lower the vehicle.

  1. Install the engine and transaxle rear mount retaining bracket.

  1. Using the special tools, raise the engine and transaxle assembly.

  1. NOTE:
    NOTE:Do not tighten the engine rear mount retaining nuts at this stage.
    NOTE:
    NOTE:Install new engine rear mount retaining nuts.
    Install the engine rear mount retaining nuts.

  1. Remove the special tools.

  1. Attach the transmission fluid cooler feed and return lines to the automatic transmission.
  1. Raise and support the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. CAUTION:
    CAUTION:The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Do not damage the halfshaft seal.
    Attach the right-hand halfshaft and the intermediate shaft to the transaxle.
    • Remove the protective sleeve before fully installing the halfshaft.

  1. NOTE:
    NOTE:Install a new center bearing cap and locknuts.
    Install the intermediate shaft center bearing cap.

  1. CAUTION:
    CAUTION:The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Do not damage the halfshaft seal.
    CAUTION:
    CAUTION:Make sure the snap ring is correctly seated.
    NOTE:
    NOTE:Install a new snap ring.
    Attach the left-hand halfshaft to the transaxle.
    • Remove the protective sleeve before fully installing the halfshaft.

  1. CAUTION:
    CAUTION:Make sure that the heat shield is installed to prevent damage to the ball joint.
    NOTE:
    NOTE:The lower arm pinch bolt must be installed from the rear of the wheel knuckle.
    Attach the lower arm to the wheel knuckle on both sides.

  1. WARNING:
    WARNING:Install a new tie-rod end retaining nut. Failure to follow this instruction may result in personal injury.
    NOTE:
    NOTE:Use a 5 mm Allen key to prevent the ball joint stud from rotating.
    Attach the right-hand tie-rod end to the wheel knuckle.

  1. NOTE:
    NOTE:Install new exhaust flange nuts and a new exhaust flange gasket.
    Attach the exhaust flexible pipe to the catalytic converter.
  1. Remove the exhaust flexible pipe support.

  1. Install the engine support insulator.

  1. Install the accessory drive belt cover.

  1. Connect the ignition switch to starter motor solenoid and battery to starter motor solenoid cables.

  1. CAUTION:
    CAUTION:Make sure the transmission fluid level indicator tube is fully located in the transmission housing.
    Install the transmission fluid level indicator tube to the transaxle.

  1. Attach the selector lever cable retaining bracket to the transaxle.

  1. Attach the selector lever cable to the manual shift lever.
  1. Adjust the selector lever cable.
    For additional information, refer to: Selector Lever Cable Adjustment (307-05 Automatic Transmission/Transaxle External Controls - Vehicles With: 4-Speed Automatic Transmission (AW81-40), General Procedures).
  1. Lower the vehicle.

  1. Connect the vehicle speed sensor (VSS) electrical connector.

  1. Connect the transmission range (TR) sensor electrical connector.

  1. Connect the transaxle wiring harness electrical connector.

  1. Connect the transaxle breather hose.

  1. Connect the turbine shaft speed (TSS) sensor electrical connector.

  1. Attach the ground cable to the transaxle.

  1. Install the engine wiring harness support brackets.

  1. Attach the engine ground cable to the transaxle.

  1. Tighten the engine rear mount outer retaining nuts.

  1. Tighten the engine rear mount center retaining nut.

  1. Install the battery tray support bracket.

  1. Tighten the strut and spring assembly top mount retaining nuts on both sides.
  1. Install the front wheels and tires.
    For additional information, refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).
  1. Install the battery tray.
    For additional information, refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation).
  1. Connect the powertrain control module (PCM) electrical connector to the PCM.
    For additional information, refer to: Powertrain Control Module (PCM) - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) (303-14 Electronic Engine Controls, Removal and Installation).
  1. Install the air cleaner.
    For additional information, refer to: Air Cleaner - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) (303-12 Intake Air Distribution and Filtering, Removal and Installation).
  1. Check the transmission fluid level and top up with clean automatic transmission fluid if necessary.
    For additional information, refer to: Transmission Fluid Level Check (307-01 Automatic Transmission/Transaxle - Vehicles With: 4-Speed Automatic Transmission (AW81-40), General Procedures).
  1. NOTE:
    NOTE:Only carry out the following step when a new transaxle has been installed.
    Using worldwide diagnostic system (WDS), reset the transmission control module (TCM).

307-02 Transmission-Transaxle Cooling - Vehicles With: 4-Speed Automatic Transmission (AW81-40) > < Vehicle Speed Sensor (VSS)