ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

ABOUT US
Transaxle - 1.8L Diesel > < Transaxle - 1.6L-1.8L-2.0L

Mondeo 1997 (08.1996-09.2000)

Manual Transmission/Transaxle - Transaxle—2.5L Mondeo 1997 (08/1996-09/2000)
Removal

Special Tool(s)

Spanner, for steering gear

211-186 (13013)

Driveshaft remover

308-192 (16057)

Adjuster, for shift lever

308-273 (16088A)

Spanner, for intake manifold

303-210 (21066)

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)
General Equipment
Retaining straps
Transmission jack
Auxiliary plugs
Hand vacuum pump
Materials
Name
Specification
Cable ties
 

Removal

All Vehicles
  1. General notes.
    • Make a note of the radio keycode.
    • Make a note of the pre-programmed radio stations.
      CAUTION:
      CAUTION:Disconnect the battery ground lead.
    • The position markings for the engine mountings and engine roll restrictors are described looking from the transmission towards the engine.
    • Sub-operations for particular variants which do not apply to all vehicles are marked clearly with a note.
    • If necessary, cut cable ties and renew when installing the assembly.

  1. Hold the shift lever using special tool.
    • Shift the gear shift mechanism to neutral.
    • Pull up the boot and bellows.

  1. Remove the air filter container.
    1. Two positive crankcase ventilation (PCV) hoses
    1. Hose clamp on throttle body
    1. Vacuum hose
    1. Mass air flow (MAF) connector
    1. Intake air temperature (IAT) sensor connector
    1. Release from rubber mount and remove.

  1. Drain brake fluid from reservoir using hand vacuum pump .

  1. NOTE:
    NOTE:New nuts do not need fitting.
    Undo the nuts on both the suspension struts five turns.

  1. Fasten the radiator on both sides (left-hand side shown).

  1. Remove the coolant pump cover.
    1. Unclip the coolant hose.
    1. Remove the bolts.
    1. Take off the coolant pump cover.

  1. Detach the cables from the bracket.
    1. Cruise control cable (if fitted)
    1. Accelerator cable

  1. Detach the ground lead and lay it to one side.

  1. Separate/pull off the vehicle speed sensor (VSS) connector and the reversing light switch.

  1. Disconnect the starter motor.

  1. Unscrew the two top flanged bolts.

  1. Fit special tool (shown with battery removed).

  1. CAUTION:
    CAUTION:Brake fluid may leak out. Observe the safety procedures for handling brake fluid.
    Detach the pressure line from the clutch slave cylinder.

  1. Detach the left-hand transmission mounting bracket from the transmission.
  1. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Drain off the transmission fluid.
    • Re-tighten the drain plug.

  1. Remove the rear three-way catalytic converter.

  1. Remove the lower wheel arch trim panels (right-hand side shown without front wheel).

  1. CAUTION:
    CAUTION:Do not damage the boots and the ABS sensor ring.
    Remove the stabiliser bar connecting link and the lower suspension arm ball joint from both sides (left-hand side shown without front wheel).

  1. Remove the lower radiator cover.

  1. Remove the bumper braces from the subframe.
Vehicles with air conditioning
  1. Remove the air-conditioning dryer.
    • Unscrew the bolts and tie the air-conditioning dryer to the side.

  1. Remove the oil line bracket from the subframe.

  1. Remove the left-hand engine roll restrictor.
    1. Unscrew the nuts.
    1. Remove the centre bolt.

  1. Remove the left-hand engine roll restrictor bracket.

  1. Remove the right-hand engine roll restrictor.
    1. Remove the centre bolt.
    1. Remove the bolts.
    1. Remove the right-hand engine roll restrictor.

  1. Remove the right-hand engine roll restrictor bracket.

  1. Undo the bolts and lower the subframe at the rear.

  1. Remove the steering gear heat shield.

  1. Remove the steering gear and tie it up (two bolts; left-hand side shown).

  1. Detach the gearshift cable and the selector cable from the transmission.
    1. Detach the gearshift cable and selector cable.
    1. Remove the nuts.
    1. Detach the bracket.

  1. WARNING:
    WARNING:Support the subframe using the transmission jack. Place a suitable wooden block underneath.
    Fully unscrew the bolts and remove the subframe.

  1. CAUTION:
    CAUTION:The inner joint must not be bent more than 18 degrees, the outer one no more than 45 degrees.
    Remove the right-hand front axle driveshaft centre bearing.
    • Detach the right-hand front axle driveshaft from the centre bearing and tie it up.
    • Remove the centre bearing together with the intermediate shaft (two nuts).

  1. CAUTION:
    CAUTION:The inner joint must not be bent more than 18 degrees, the outer one no more than 45 degrees.
    Detach the left-hand driveshaft.
    • Detach the left-hand driveshaft using special tool and tie it up.

  1. Support the transmission with transmission jack , place onto wooden blocks and secure with retaining strap .

  1. Unscrew the bottom three rear flanged bolts (right-hand engine roll restrictor bracket shown installed).

  1. Unscrew the bottom three front flanged bolts (left-hand engine roll restrictor bracket shown installed).
  1. Lower the engine and transmission assembly slightly using special tool 303-290.
  1. Separate the transmission from the engine and lower it with a transmission jack .

  1. Remove any attachments or add-ons that are fitted to the transmission.
    1. Starter (two bolts).
    1. VSS

Transaxle - 1.8L Diesel > < Transaxle - 1.6L-1.8L-2.0L