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

Focus 2004.75 (07.2004-)

Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75) - Transaxle—2.0L Duratec-HE (MI4) 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

Adapter for 303-290A

303-290A-15
General Equipment
Transmission jack
Retaining straps
Materials
Name
Specification
High-temperature grease
ESD-M1C220-A 
Transmission fluid
WSD-M2C200-C 

Installation

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

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

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

  1. Install the left-hand transmission bolt.
  1. Remove the retaining straps.
  1. Remove the transmission jack.

  1. Install the transmission right-hand retaining bolts.

  1. Install the transmission lower retaining bolts.

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

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

  1. NOTE:
    NOTE:Install new bolt on the rear engine mounting.
    NOTE:
    NOTE:Do not tighten the rear engine mounting bolt for the moment.
    Install bolt on the rear engine mounting.
  1. Raise the vehicle.
    For additional information, refer to: Jacking (100-02 Jacking and Lifting, Description and Operation) /
    Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. Remove the special tools.

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

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

  1. Attach the starter motor to the engine.

  1. Attach the wiring harness bracket to the engine.
  1. Lower the vehicle.

  1. Remove the special tool on both sides (right-hand side shown).
  1. Remove the cable ties from the radiator.
  1. Install the headlamp assembly on both sides.
    For additional information, refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
  1. Raise the vehicle.
    For additional information, refer to: Jacking (100-02 Jacking and Lifting, Description and Operation) /
    Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. NOTE:
    NOTE:Install new flexible pipe gaskets and nuts.
    Attach the exhaust flexible pipe to the catalytic converter.

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

  1. Hook the flexible pipe into the crossmember rubber insulators.

  1. Install the cross brace.
  1. Install the left-hand halfshaft.
    For additional information, refer to: Front Halfshaft LH (205-04 Front Drive Halfshafts, Removal and Installation).
  1. Install the right-hand halfshaft.
    For additional information, refer to: Rechte Antriebswelle - 3-Türer (205-04 Vorderradantriebswellen, Removal and Installation).

  1. Install the engine roll restrictors.

  1. Install the crash box.
    1. Insert the M10 x 16 bolt.
    1. Insert the M10 x 25 bolts.
  1. Lower the vehicle.

  1. Install the transmission upper retaining bolts.
    • Attach the ground lead to the transmission.

  1. Tighten the bolt on the rear engine mounting.

  1. CAUTION:
    CAUTION:If brake fluid comes into contact with the paintwork, rinse off the affected areas with cold water without delay.
    Connect the clutch slave cylinder line to the clutch slave cylinder.
    • Attach the clutch slave cylinder pipe to the bracket.
    • Install the spring clip.
  1. Bleed the clutch system.
    For additional information, refer to: Kupplungssystem entlüften (308-00 Schaltgetriebe und Kupplung - Allgemeine Informationen, General Procedures).

  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. Attach the ground lead to the rear engine mounting bracket.
    • Attach the wiring harness bracket to the rear engine mounting bracket.

  1. Attach the reversing lamp switch connector.
  1. Install the battery carrier.
    For additional information, refer to: Batteriekonsole - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma)/1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (414-01 Batterie, Befestigung und Batteriekabel, Removal and Installation).
  1. Install the air cleaner.
    For additional information, refer to: Luftfilter - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (303-12 Ansaugsystem, Removal and Installation).

  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. Raise the vehicle.
    For additional information, refer to: Jacking (100-02 Jacking and Lifting, Description and Operation) /
    Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. Install the lower engine cover.

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

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