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In-vehicle Repair|Disassembly > < Transaxle - 2.5L Duratec-VE (VE6)-3.0L Duratec-SE (VE6)-3.0L Duratec-ST (VE6)

Mondeo 2001 (10.2000-02.2007)

Manual Transmission/Transaxle - Vehicles With: 6-Speed Manual Transmission (MMT6) - Transaxle—2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel Mondeo 2001 (10/2000-02/2007)
Removal

Special Tool(s)

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)

Remover, Halfshaft

308-192 (16-057)
General Equipment
Transmission jack
Retaining straps

Removal
  1. Remove the engine cover.
    • Remove the oil dipstick tube.
    • Remove the oil filler cap.

  1. Remove the strut mount reinforcement cover.

  1. Loosen the strut top mount nuts by four turns, on both sides.

  1. Remove the air cleaner.
    1. Detach the air cleaner intake hose from the front fender.
    1. Detach the positive crankcase ventilation (PCV) hose from the cylinder head cover.
    1. Detach the turbocharger intake hose from the turbocharger.
    1. Detach the vacuum hose from the air cleaner housing.
  1. Remove the battery carrier.
    For additional information, refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).

  1. Disconnect the reverse light switch electrical connector.

  1. CAUTION:
    CAUTION:If brake fluid comes into contact with the paintwork, rinse off the affected areas with cold water without delay.
    CAUTION:
    CAUTION:Close off the clutch slave cylinder pipe to prevent fluid loss or dirt ingress.
    Detach the clutch slave cylinder pipe from the clutch slave cylinder.
    • Detach the clutch slave cylinder pipe from the bracket.
    • Remove the spring clip.

  1. Detach the gearshift cables from the transmission.
    1. Detach the gearshift and selector cables from the selector mechanism.
    1. Press the locking pins together and detach the gearshift cables from the abutment.
  1. Raise the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation) /
    Jacking (100-02 Jacking and Lifting, Description and Operation).
  1. Remove the subframe.
    For additional information, refer to: Subframe (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).

  1. Separate the intercooler outlet pipe from the turbocharger intake hose.

  1. Detach the intercooler outlet pipe from the intercooler.
    • Remove the hose clamp.
    • Remove the bolt.

  1. Remove the intercooler outlet pipe.

  1. Detach the coolant pipe bracket from the transmission.

  1. CAUTION:
    CAUTION:Secure the halfshaft to prevent damage to the constant velocity joints. 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.
    CAUTION:
    CAUTION:Close off the transmission openings to prevent fluid loss or dirt ingress.
    Detach the right-hand halfshaft together with the intermediate shaft from the transmission and secure it to one side.
    • Unscrew and discard the bearing cap and the self-locking nut of the intermediate shaft centre bearing.
    • Allow the transmission fluid to drain into a suitable container.

  1. CAUTION:
    CAUTION:Secure the halfshaft to prevent damage to the constant velocity joints. 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.
    CAUTION:
    CAUTION:Close off the transmission openings to prevent fluid loss or dirt ingress.
    Using the special tool, detach the left-hand halfshaft from the transaxle and secure it to one side.
    • Discard the snap ring.
    • Allow the transmission fluid to drain into a suitable container.
  1. Lower the vehicle.

  1. Detach the ground cable from the transmission.

  1. Attach the special tools.

  1. Remove the engine rear mounting assembly.
    • Discard the nuts.

  1. Lower the engine / transmission assembly using the special tools.
  1. Detach the wiring harness from the transmission.

  1. Detach the wiring harness bracket from the engine.

  1. Slacken the starter motor bolts by three turns.

  1. Remove the rear engine mounting bracket.

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

  1. Remove the right-hand transmission bolts.

  1. Remove the left-hand transmission bolts.

  1. Secure the transmission on the transmission jack using suitable retaining straps.
  1. Support the transmission using the transmission jack and remove.

In-vehicle Repair|Disassembly > < Transaxle - 2.5L Duratec-VE (VE6)-3.0L Duratec-SE (VE6)-3.0L Duratec-ST (VE6)