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Manual Transaxle > < Transaxle - 1.6L Duratorq-TDCi (DV) Diesel

Focus 2004.75 (07.2004-)

Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75) - Transaxle—1.8L Duratorq-TDCi (Lynx) Diesel Focus 2004.75 (07/2004-)
Installation

Special Tool(s)

Support Bar, Engine

303-290A

Adapter for 303-290A

303-290-03A

Adapter for 303-290A

303-290-13

Adapters for 303-290A

303-290A-15, 303-290A-15/5, 303-290A-15/6, 303-290A-15/7
General Equipment
Transmission jack
Retaining straps
Materials
Name
Specification
High-temperature grease
ESD-M1C220-A 
Grease
SA-M1C9107-A 
Transmission fluid
WSD-M2C200-C 

Installation

CAUTION:
CAUTION:Ensure that the two guide sleeves are installed.
All vehicles
  1. Raise the vehicle. For additional information, refer to: (100-02 Jacking and Lifting)
    Lifting (Description and Operation),
    Jacking (Description and Operation).
  1. Secure the transmission on the transmission jack using suitable retaining straps.
  1. If required, thinly coat the input shaft splines with grease.

  1. Move the transmission into position using the transmission jack and install it.

  1. NOTE:
    NOTE:Perform this and the following operation simultaneously.
    Install the left-hand transmission bolt.

  1. Install the right-hand transmission bolts.
  1. Remove the securing straps.
  1. Remove the transmission jack.

  1. Install the left-hand transmission bolt.

  1. Install the transmission lower bolts.

  1. Attach the starter motor to the transmission.
    • Install the ground lead on the transmission.

  1. Install the rear engine mounting bracket (rear engine mounting shown removed for clarity).

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

  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: (100-02 Jacking and Lifting)
    Lifting (Description and Operation),
    Jacking (Description and Operation).

  1. Remove the special tool.

  1. Remove the special tool.
    • Remove the nut.

  1. Remove the special tool.

  1. Connect the crankshaft position sensor (CKP) electrical connector.

  1. Attach the coolant pipe bracket to the engine.
    • Screw on the nuts.
    • Connect the cable connector.
  1. Install the halfshafts. For additional information, refer to: (205-04 Front Drive Halfshafts)
    Front Halfshaft LH (Removal and Installation),
    Front Halfshaft RH (Removal and Installation).

  1. Install the engine roll restrictor rubber mount.

  1. Install the catalytic converter bracket.
    • Slide the catalytic converter forward.

  1. WARNING:
    WARNING:The flexible exhaust pipe must not be twisted by more than two degrees. Failure to follow this instruction may result in damage to the flexible exhaust pipe.
    NOTE:
    NOTE:Install a new flexible exhaust pipe gasket and nuts.
    NOTE:
    NOTE:Use the tyre lever to prevent the flexible exhaust pipe from twisting when tightening the nuts.
    Connect the catalytic converter to the flexible exhaust pipe.
    • Coat the catalytic converter stud with grease before installing.

  1. Attach the flexible exhaust pipe to the rubber straps on the crossmember.

  1. NOTE:
    NOTE:Install new exhaust manifold assembly nuts.
    Tighten the exhaust manifold nuts in the stated sequence.

  1. Detach the support sleeve or the reinforcement from the flexible exhaust pipe.

  1. Install the reinforcement brace (if equipped).

  1. Install the crashbox.
    1. Install the M10 x 16 bolt.
    1. Install the M10 x 25 bolts.
  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. Install the transmission upper bolts.

  1. Attach the coolant pipe bracket to the transmission.

  1. Install the turbocharger intercooler air pipe.

  1. Attach the turbocharger intercooler air pipe to the transmission.
    • Screw on the nuts for the air pipe bracket.
    • Tighten the hose clip.

  1. WARNING:
    WARNING:If brake fluid comes into contact with the paintwork, the affected area must be washed down immediately with cold water.
    Connect the clutch slave cylinder line 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: Clutch System Bleeding (308-00 Manual Transmission/Transaxle and Clutch - General Information, General Procedures).

  1. Connect the reversing lamp switch electrical connector.

  1. Install the ground lead on the transmission.
    • Attach the pipe bracket to the transmission.

  1. Attach the gearshift cables to the abutment.
    1. Attach the gearshift cable to the abutment and secure by turning the catches clockwise.
    1. Attach the selector cable to the abutment and secure by turning the catches clockwise.

  1. Install the gearshift cables on the shift mechanism.
    1. Press the gearshift cable catch and attach the gearshift cable to the gear lever.
    1. Press the selector cable catch and attach the selector cable to the selector lever.
  1. Adjust the selector cable.
    For additional information, refer to: Schaltseilzug einstellen - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (MTX-75) (308-00 Schaltgetriebe und Kupplung - Allgemeine Informationen, General Procedures).

  1. Connect the outlet pipe to the intercooler outlet hose.

  1. Tighten the bolt of the rear engine mounting.
  1. Raise the vehicle. For additional information, refer to: (100-02 Jacking and Lifting)
    Lifting (Description and Operation),
    Jacking (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. Lower the vehicle.
  1. Remove cable tie from bonnet lock security panel.
  1. Install the battery tray.
    For additional information, refer to: Batteriekonsole - 1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel (414-01 Batterie, Befestigung und Batteriekabel, Removal and Installation).
  1. Install the air cleaner.
    For additional information, refer to: Luftfilter - 1.8L Duratorq-TDCi (Lynx) Diesel (303-12 Ansaugsystem, Removal and Installation).
  1. Raise the vehicle. For additional information, refer to: (100-02 Jacking and Lifting)
    Lifting (Description and Operation),
    Jacking (Description and Operation).

  1. With the vehicle on a level surface, fill the transmission with transmission fluid until the fluid level is just below the filler hole.

  1. Install the engine undershield.
  1. Lower the vehicle.
Vehicles with global closing
  1. Initialize the window winder motors.
    For additional information, refer to: Motor - elektrischer Fensterheber initialisieren (501-11 Fenster, Rahmen und Betätigungsmechanismen, General Procedures).

Manual Transaxle > < Transaxle - 1.6L Duratorq-TDCi (DV) Diesel