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Manual Transaxle > < Transaxle - 2.5L

Mondeo 1997 (08.1996-09.2000)

Manual Transmission/Transaxle - Transaxle—1.8L Diesel Mondeo 1997 (08/1996-09/2000)
Installation

Special Tool(s)

Spanner, for steering gear

211-186 (13013)

Subframe locating pins

205-316 (15097A)

Engine support bar

303-290 (21140)

Adapter for 303-290

303-290-01 (2114001)

Adapter for 303-290

303-290-02 (2114002)

Adapter for 303-290

303-290-03 (2114003)

Adjuster, for shift lever

308-273 (16088A)

Alignment gauge, for powertrain

502-003 (21172)
General Equipment
Transmission jack
Retaining strap
Materials
Name
Specification
Cable ties
 
High-temperature grease
ESD-M2G269-A 
Brake fluid
ESD-M6C57-A 

Installation

All Vehicles
  1. Prepare the transmission for installation.

  1. Move the transmission into position using the transmission jack.
    Screw in the flange bolts on the right-hand transmission side and attach the catalytic converter bracket.

  1. Screw in the flange bolts and fit the starter motor.
    1. Screw in the flange bolts.
    1. Tighten the starter motor nuts.
    1. Attach the starter motor bracket.

  1. Fit the bracket for the left-hand engine roll restrictor.

  1. NOTE:
    NOTE:The adjusting mechanism must be unlocked.
    Attach the gearshift cables to the transmission and adjust them.
      NOTE:
      NOTE:The abutment brackets are tensioned automatically once they are released.
    1. Slacken the abutment bracket by turning it anti-clockwise and fit the cable in the bracket.
    1. Connect the selector cable to the gear selector lever.
    1. Slacken the abutment bracket by turning it anti-clockwise and fit the cable in the bracket.
    1. Connect the shift cable to the gearshift lever.
    1. Lock the adjusting mechanism by pressing in the tab.
  1. Lower the vehicle.
  1. Raise the engine with transmission to installation height.

  1. CAUTION:
    CAUTION:Screw in the nuts until they make contact, then slacken them one turn.
    Attach the rear engine support bracket to the transmission.

  1. CAUTION:
    CAUTION:Screw in the nuts until they make contact, then slacken them one turn.
    Attach the front engine mounting bracket.

  1. Connect the plug and attach the wiring harness to the transmission.
    1. Connect the plug to the reversing light switch.
    1. Connect the plug for the vehicle speed sensor (VSS) and clip it into the bracket.
    1. Route the wiring and attach the wiring harness bracket to the transmission.
  1. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. CAUTION:
    CAUTION:The inner joint must not be bent more than 18 degrees, the outer one no more than 45 degrees.
    NOTE:
    NOTE:Make sure the snap-ring locates correctly.
    Fit the left-hand front driveshaft.
    • Fit the front driveshaft with its new snap-ring into the transmission.

  1. CAUTION:
    CAUTION:The inner joint must not be bent more than 18 degrees, the outer one no more than 45 degrees.
    NOTE:
    NOTE:Lower nut with refrigerant pipe bracket.
    Install the right-hand front axle driveshaft.
    • Fit the front axle driveshaft in the transmission, centre bearing bracket and wheel hub.

  1. NOTE:
    NOTE:Screw in the nuts until they make contact, then slacken them one turn.
    Fit the subframe.
    • Detach the front engine roll restrictor from the subframe.
    • Align the steering gear.

  1. Align the subframe.
    • Insert the special tools.
    • Align the subframe so that the special tools are centred in the body centring holes on the left and right (left-hand side shown).

  1. NOTE:
    NOTE:The subframe must not move during the tightening operation.
    Secure the subframe.
    1. Tighten the bolts working diagonally.
    1. Remove the special tools.

  1. Align the engine/transmission assembly.
    1. Fit the special tool in the place of the left-hand engine roll restrictor.
    1. Screw in the bolts.
    1. Fit the centre bolt and tighten by hand.
  1. Lower the vehicle.

  1. CAUTION:
    CAUTION:Do not distort or turn the engine mounting.
    Tighten the rear engine mounting bracket nuts.
    • Tighten the air filter bracket.

  1. CAUTION:
    CAUTION:Do not distort or turn the engine mounting.
    Tighten the front engine mounting bracket nuts.

  1. Remove the special tools.
  1. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Attach the bracket of the right-hand engine roll restrictor to the transmission.

  1. CAUTION:
    CAUTION:Do not tilt the engine roll restrictor.
    Attach the right-hand engine roll restrictor.
    • Fit the centre bolt.
    1. Tighten the bolts.
    1. Tighten the centre screw.

  1. CAUTION:
    CAUTION:Do not tilt the engine roll restrictor.
    Attach the left-hand engine roll restrictor.
    • Detach the gauge.
    • Move the engine roll restrictor into position.
    1. Tighten two bolts.
    1. Tighten the centre screw.

  1. Attach the steering gear to the subframe.

  1. CAUTION:
    CAUTION:Do not damage the boots and the ABS sensor ring.
    Attach the stabiliser link rod and the suspension lower arm ball joint on both sides.

  1. Attach the right-hand and left-hand bumper bar brace to the subframe (right-hand side shown).

  1. Attach the power steering pipe to the subframe.

  1. Attach the power steering pipe to the subframe (continued).
Vehicles with air conditioning
  1. Attach the air conditioning dryer to the subframe.
All vehicles
  1. Fit the left and right-hand lower wheel arch trim panels (right-hand side shown).

  1. Attach the lower radiator cover.
  1. Fit the front wheels.

  1. Attach the engine undershield (if fitted).
  1. Lower the vehicle.

  1. Connect together two engine main wiring harness connectors.
    • Route the engine main wiring harness and secure with cable ties .

  1. CAUTION:
    CAUTION:Brake fluid may leak out. Observe the safety procedures for handling brake fluid.
    Connect the high-pressure pipe to the clutch slave cylinder.
    1. Fit the high-pressure pipe in the bracket.
    1. Fit the spring clip in the slave cylinder pipe.

  1. NOTE:
    NOTE:One bolt with ground lead.
    Screw in the upper flange bolts.

  1. NOTE:
    NOTE:Use a new gasket.
    Attach the catalytic converter to the exhaust manifold.

  1. Attach the power steering pipe to the bracket and push on the EGR valve hose.

  1. Fit the air cleaner.
    • Fit the air cleaner.
    1. Clip on the air cleaner intake.
    1. Push on the vacuum hose.
    1. Tighten the hose clip.
    1. Connect the MAF connector.

  1. Tighten the wheel nuts for both wheels.

  1. Tighten the left-hand suspension nut strut (right-hand side shown).
    • Counterhold using an Allen key.
    • Tighten until finger-tight using a ring spanner.
    • Tighten to specified torque using a torque wrench.

  1. Remove the special tool from the selector gate and fit the boot and bellows.
  1. Bleed the hydraulic clutch system. For additional information, refer to Section  308-00 Manual Transmission/Transaxle and Clutch - General Information.
  1. Standard finishing operations.
    • Connect the battery ground cable.
    • Enter the radio keycode.
    • Reprogram the preset radio stations.
    • Carry out a road test to enable the PCM to collect data.
    • Check the routing of the vacuum hoses and wiring and secure them with cable ties .
    • Check fluid levels and correct if necessary.

Manual Transaxle > < Transaxle - 2.5L