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Ford Workshop Service and Repair Manuals

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Transaxle - 2.0L Duratorq-Di-TDDi (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel > < Transaxle - 2.5L Duratec-VE (VE6)

Mondeo 2001 (10.2000-02.2007)

Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75) - Transaxle—3.0L Duratec-ST (VE6) Mondeo 2001 (10/2000-02/2007)
Installation

Special Tool(s)

Protector, Halfshaft Seal

205-775

Support Bar, Engine

303-290A (21-140A)

Adapter for 303-290A

303-290-01 (21-140-01)

Adapter for 303-290A

303-290-02 (21-140-02)

Adapter for 303-290A

303-290-03A (21-140-03A)

Adapter for 303-290A

303-290-05A (21-140-05A)

Adapter for 303-290A

303-290A-14
General Equipment
Transmission jack
Securing straps
Materials
Name
Specification
High-Temperature Grease
ESD-M1C220-A 
Transmission Fluid
WSD-M2C200-C 

Installation

All vehicles
  1. CAUTION:
    CAUTION:Ensure that the two guide sleeves are installed.
    Raise and support the vehicle. For additional information, refer to: (100-02 Jacking and Lifting)
    Lifting - 3.0L Duratec-ST (VE6) (Description and Operation),
    Jacking - 3.0L Duratec-ST (VE6) (Description and Operation).
  1. Secure the transaxle on the transmission jack using suitable securing straps.
  1. Coat the input shaft splines with a thin coating of grease.

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

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

  1. Install the transaxle lower retaining bolt.

  1. Install the catalytic converter retaining bracket.

  1. Install the transaxle left-hand retaining bolts.

  1. Install the transaxle upper retaining bolts.
    • Attach the ground cables to the transaxle.

  1. Install the engine rear mount bracket.

  1. NOTE:
    NOTE:Install new clutch slave cylinder supply line support bracket retaining nuts.
    Install the clutch slave cylinder supply line support bracket.

  1. Attach the clutch slave cylinder supply line to the support bracket.
  1. Lower the vehicle.

  1. Using the special tools, raise the engine and transaxle assembly.

  1. NOTE:
    NOTE:Install a new engine rear mount center retaining nut.
    NOTE:
    NOTE:Do not fully tighten the engine rear mount retaining nuts at this stage.
    Install the engine rear mount.

  1. Remove the special tools.

  1. Install the cowl panel.
  1. Raise and support the vehicle. For additional information, refer to: (100-02 Jacking and Lifting)
    Lifting - 3.0L Duratec-ST (VE6) (Description and Operation),
    Jacking - 3.0L Duratec-ST (VE6) (Description and Operation).

  1. CAUTION:
    CAUTION:Support the halfshaft. The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Ensure that the halfshaft oil seal is not damaged.
    CAUTION:
    CAUTION:Ensure that the snap ring is correctly located in the groove.
    NOTE:
    NOTE:Install a new snap ring.
    Attach the left-hand halfshaft to the transaxle.
    • Remove the special tool before fully installing the halfshaft.

  1. CAUTION:
    CAUTION:Support the halfshaft. The inner constant velocity joint must not be bent by more than 18 degrees. The outer constant velocity joint must not be bent by more than 45 degrees.
    CAUTION:
    CAUTION:Ensure that the halfshaft oil seal is not damaged.
    Attach the right-hand halfshaft to the transmission together with the intermediate shaft.
    • Remove the special tool before fully installing the halfshaft.

  1. NOTE:
    NOTE:Install new intermediate shaft center bearing self-locking nuts.
    Install the intermediate shaft center bearing self-locking nuts.

  1. Connect the vehicle speed sensor (VSS) electrical connector.

  1. Attach the VSS wiring harness to the bracket.

  1. Connect the starter motor electrical connectors.
    • Attach the electrical connector to the transaxle.
  1. Install the subframe.
    For additional information, refer to: Subframe (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).

  1. Attach the gearshift cables to the bracket and turn the abutment sleeves counterclockwise.
  1. Attach the gearshift cables to the selector levers.
  1. Lower the vehicle.

  1. Tighten the engine rear mount retaining nuts.

  1. Connect the reversing lamp switch electrical connector.

  1. CAUTION:
    CAUTION:If brake fluid is spilt on the paintwork, the affected area must be immediately washed down with cold water.
    Connect the clutch slave cylinder supply line to the transaxle.
    • Install the spring clip.

  1. Install the intake air cleaner.
    1. Attach the hose clamp to the intake air cleaner outlet pipe.
    1. Connect the positive crankcase ventilation (PCV) hose.
    1. Connect the mass air flow (MAF) sensor electrical connector.

  1. NOTE:
    NOTE:Install new strut and spring assembly top mount retaining nuts.
    Tighten the strut and spring assembly top mount retaining nuts on both sides.

  1. Install the strut and spring assembly top mount brace cover on both sides.
  1. Adjust the gearshift cables.
    For additional information, refer to: Gearshift Cable Adjustment - Vehicles With: MTX-75/5-Speed Manual Transaxle (308-00 Manual Transmission/Transaxle and Clutch - General Information, General Procedures).
  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 battery ground cable.
    For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
  1. Check the transmission fluid level and top up with transmission fluid, if necessary.
    For additional information, refer to: Fill Procedure (308-03A Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), General Procedures).
Vehicles with power windows
  1. Initialize the door window motors.
    For additional information, refer to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General Procedures).

Transaxle - 2.0L Duratorq-Di-TDDi (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel > < Transaxle - 2.5L Duratec-VE (VE6)