ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

ABOUT US
Manual transmission-Transaxle (VXT 75 manual transmission with 2,3 DOHC engine) Remove and Install (16 114 0) > < 316-01 VXT 75 Manual Transmission and Clutch|Description and Operation

Galaxy 1995 (02.1995-03.2000)

Manual transmission/Transaxle (VXT 75 manual transmission with 2,0 DOHC engine) Remove and Install (16 114 0)Galaxy 1995 (02/1995-03/2000)
Print Print
Removal and Installation
Special Tools

303‐290 (21‐140) Engine support bar

303‐290‐03 (21‐140‐03) Adaptor for 303‐290/21‐140

303‐290‐04 (21‐140‐04) Adaptor for 303‐290/21‐140

303‐290‐05 (21‐140‐05) Adaptor for 303‐290/21‐140

303‐290‐06 (21‐140‐06) Adaptor for 303‐290/21‐140

303‐290‐07 (21‐140‐07) Adaptor for 303‐290/21‐140
Workshop Equipment
Transmission jack
Retaining strap
Materials
Manual transmission fluidWSD‐M2C200‐C
Brake and clutch fluid DOT4SAM 6C9103 A
Cable ties
2 washers, ∅ 30 mm, 3 mm thick
Proprietary Tools
Tyre lever
Remove
1. Preparatory measures:
• Make a note of the radio keycode.
• Make a note of the preset radio stations.

CAUTION:

Disconnect the battery negative lead.

2. Detach the left‐hand front wheel.
• Slacken the wheel bolts.
• Raise the vehicle.

3. Remove the engine undershield (four bolts, two nuts) (right‐hand side shown).
   Lower the vehicle.

4. Pull out the headlamp cover (if present).

5. Remove the upper part of the air cleaner housing.
1. Pull off the mass air flow (MAF) connector.
2. Detach the intake hose from the air cleaner housing (one clamp).
3. Open the three clips.

NOTE:

Unclip the circlip.
6. Remove the lower part of the air cleaner housing (push fit).
   Pull off the breather hose.

7. Detach the secondary air injection hose from the secondary air injection pump (only vehicles with secondary air system).

8. Remove the alternator air cooling hose.
9. Raise the vehicle.

10. Remove the front exhaust pipe.
1. Flange bolts
2. Exhaust manifold nuts
3. Bracket bolt.
4. Rubber insulator.

11. Dismantle the right‐hand and left‐hand wheel suspensions (right‐hand side shown).
1. Detach the stabiliser link rod.
2. Disconnect the transverse arm ball joint from the spindle carrier (two bolts).

12. Detach the steering gear from the front axle crossmember and tie it up.

13. Detach the engine roll restrictor from the transmission.

NOTE:

Support the front axle crossmember using a transmission jack.
14. Detach the front axle crossmember and lower it.

CAUTION:

The CV joint nearest the wheel must not be bent more than 50° and the one nearest the transmission no more than 20°.

NOTE:

Escaping oil: Close off the transmission with auxiliary plugs.
15. Detach the right‐hand front axle driveshaft.
1. Detach the front axle driveshaft centre bearing from the cylinder block bracket.

NOTE:

Push the wheel suspension outwards.
2. Pull out the front axle driveshaft and tie it up to one side.
• Remove the circlip.

CAUTION:

The CV joint nearest the wheel must not be bent more than 50° and the one nearest the transmission no more than 20°.

NOTE:

Escaping oil: Close off the transmission with auxiliary plugs.
16. Detach the left front axle driveshaft and tie it up to one side.
   Remove the circlip.

17. Lower the vehicle.

CAUTION:

Working carelessly can cause damage to the hood paintwork.
18. Remove the bump stops (right‐hand side shown).
   Open the hood until it reaches its stop.

19. Take out the inner bolts of the rear engine mounting.

CAUTION:

Do not damage the fender paintwork.
20. Attach the engine support bar.
1. Attach both engine support bar adaptors using the existing bodywork bolts.

NOTE:

Push the adaptors outwards before tightening the engine support bar in place.
2. Install the engine support bar and support it on the battery tray using washers (diameter 30 mm/ thickness 3 mm).

NOTE:

Hang the chains vertically.
3. Attach the shackles to the engine lifting eyes using the chains and slightly lift the engine.

CAUTION:

The chains of the engine support bar must be tight.
21. Remove the front engine mounting bracket.
1. Three bolts.
2. Two nuts.
• Detach the ground strap.

22. Pull off the plug of the reversing light switch.

23. Take out the two upper engine/transmission flange bolts.
• Remove the heating coolant hose with the battery ground lead.
• Unscrew the two studs.
24. Lower the engine/transmission assembly using the engine support bar.
25. Carefully raise the vehicle.

26. Disconnect the starter motor.
1. Lead (terminal 30).
2. Connector (terminal 50)
3. Detach the wiring bracket.

WARNING:

Brake fluid will escape. Observe the safety regulations for working with brake fluid.
27. Separate the clutch hydraulic line.
1. Remove the spring clip.
2. Separate the quick‐release coupling and close off the hydraulic line using a 10 mm plug.

CAUTION:

Do not support on the gear shift cables.
28. Detach the shift cable bracket.
   Unclip both gearshift cables from the ball sockets and brackets.

29. Detach the transmission from the rear engine mounting.
   Unscrew the central bolt.
30. Take out the two flange bolts (left‐hand side).
   Support the transmission with a transmission jack.

31. Remove the flange bolts (right‐hand side).
• Pull off the connector for the vehicle speed sensor (VSS).

32. Take out the flange bolts (underneath).

CAUTION:

Support the transmission on wooden wedges and secure it to the transmission jack with a retaining strap.
33. Separate the transmission from the engine and lower it.
Install

CAUTION:

If the old transmission was equipped with a starter motor bearing bush, then a bearing bush must be installed in the new transmission.
34. Drive the new starter motor bearing bush home using a suitable drift.

CAUTION:

Support the transmission on wooden wedges and secure it to the transmission jack with a retaining strap.
35. Bring the transmission into position using the transmission jack.

36. Tighten the flange bolts (underneath).

37. Tighten the flange bolts (right‐hand side).
38. Connect the VSS multiplug.

39. Install the transmission to the rear engine mounting.
   Tighten the central bolt.
40. Tighten the two flange bolts (left‐hand side).
41. Remove the retaining strap and transmission jack.

CAUTION:

Do not support on the gear shift cables.
42. Install the retaining bracket for the shift cables.
   Clip the gearshift cables into the ball socket and bracket.

NOTE:

Make sure that the spring clip engages correctly.
43. Connect the clutch hydraulic pipe.
1. Remove the 10 mm plug and connect the quick release coupling.
2. Install the spring clip.

44. Connect the starter motor.
1. Install the cable (terminal 30).
2. Push on the connector (terminal 50).
3. Install the cable guide.

45. Tighten the two upper engine/transmission flange bolts.
1. Tighten the two studs.
2. Connect the heater coolant hose and the battery negative lead.
46. Carefully lower the vehicle.
47. Raise the engine/transmission assembly using the engine support bar.

48. Connect the plug of the reversing lamp switch.

NOTE:

Do not tighten the bolts yet.
49. Install the front engine mounting bracket.
1. Three bolts.
2. Two nuts.

CAUTION:

Do not damage the fender paintwork.
50. Remove the engine support bar.
   Screw the bodywork bolts back into the fenders.

51. Put the inner bolts into the rear engine mounting and tighten all the bolts.

52. Tighten the bolts and nuts of the front engine mounting bracket.
1. Two nuts.
2. Three bolts.
• Connect the ground strap.

53. Install the bump stops (right‐hand side shown).
   Raise the vehicle.

CAUTION:

The CV joint nearest the wheel must not be bent more than 50° and the one nearest the transmission no more than 20°.

CAUTION:

Do not damage the oil seal when inserting the front axle driveshaft.
54. Install the left‐hand front axle driveshaft using a new circlip.

CAUTION:

The CV joint nearest the wheel must not be bent more than 50° and the one nearest the transmission no more than 20°.

CAUTION:

Do not damage the oil seal when inserting the front axle driveshaft.
55. Install the right‐hand front axle driveshaft using a new circlip.
   Put in the front axle driveshaft and fit the driveshaft centre bearing to the bracket on the cylinder block.

NOTE:

Move the front axle crossmember into position using a transmission jack.
56. Install the front axle crossmember.
1. Short bolts.
2. Long bolts.

NOTE:

Tightening torques, engine roll restrictor to transmission. Engine roll restrictor made of steel = 98 Nm, engine roll restrictor made of aluminium = 70 Nm.

NOTE:

The bolts for the engine roll restrictor made of aluminium have a different length. Bolt length = 88 mm; tighten to 60 Nm + 90 degrees.
57. Attach the engine roll restrictor to the transmission.

NOTE:

Renew the locknuts, coat the bolts with thread‐locking compound.
58. Attach the steering gear to the front axle crossmember.

59. Assemble the left‐hand and right‐hand suspensions (right‐hand side shown).
1. Attach the stabiliser link rod.
2. Connect the transverse arm ball joint to the spindle carrier (two bolts).

60. Install the front exhaust pipe using a new gasket.
1. Rubber insulator.
2. Exhaust manifold nuts
3. Flange bolts
4. Bracket bolt.

WARNING:

On 16 inch aluminium wheels tighten the wheel nuts to 170 Nm.
61. Attach the left‐hand front wheel.
• Lower the vehicle.
• Tighten the wheel bolts.

62. Attach the secondary air injection hose to the secondary air injection pump (only vehicles with secondary air system).

63. Install the alternator air cooling hose.

NOTE:

Push it into the three guides. Insert the circlip.
64. Install the lower part of the air cleaner housing (push fit).
   Push on the engine breather valve.

65. Install the upper part of the air cleaner housing and intake hose.
1. Close the edge clips.
2. Install the intake hose on the air cleaner housing (one clamp).
3. Push on the MAF connector.

66. Install the headlamp cover (if removed).

67. Install the battery and connect it.
68. Install the upper part of the engine compartment/battery intermediate panel.
• Attach the relay.

69. Finishing operations.
• Check fluid levels and top up as necessary.
• Secure the cables and hoses with cable ties.
• Check the engine and cooling system for leaks.
• Bleed the hydraulic clutch system as detailed in Operation No. 16 843 0.
• Raise the vehicle.

NOTE:

The fill level is to the bottom edge of the filler hole.
70. Check the transmission oil level and correct it if necessary (Ford specification WSD‐M2C200‐C).
   Tighten the filler plug.

71. Install the engine undershield (four bolts, three nuts) (right‐hand side shown).
   Lower the vehicle.
72. Finishing operations (cont.).
• Enter the radio keycode.
• Reprogramme the preset radio stations.
• Set the clock.
• Carry out a road test to enable the PCM to collect data.

Manual transmission-Transaxle (VXT 75 manual transmission with 2,3 DOHC engine) Remove and Install (16 114 0) > < 316-01 VXT 75 Manual Transmission and Clutch|Description and Operation