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Transmission Assembly ‐ Dismantle and Reassemble (Transmission Removed) (16 118 8) > < SpecificationsGeneral Specifications

Transit 1995 (08.1994-07.2000)

Remove and install transmission (16 114 0)Transit 1995 (08/1994-07/2000)
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Removal and Installation
Transmission Assembly with 2,5 Diesel Engine
Special Tools

24‐003Remover/installer, radiator hose clamp
Materials
Description
High‐temperature greaseESD‐M1C220‐A
Thread locking compoundSDM‐M4G9107‐A
Driveshaft pilot bearingFinis code 1042972
Transmission fluidESD‐M2C186‐A
Workshop Equipment
Transmission jack
Clamping strap
Remove
1. General note.
   When removing coolant or vent hoses, use the radiator hose clamp remover/installer 24‐003 if necessary.
2. Standard preparations.
• Make a note of the radio keycode.

CAUTION:

After noting the preset radio stations, disconnect the battery negative lead.
• Make a note of the preset radio stations.
Vehicles with automatic clutch
3. Disconnect the gear lever knob sensor connector.
All vehicles
4. Remove the gear lever.
   Pull up the rubber gaiter.
1. Noise damping pad
2. Screws
Vehicles with automatic clutch
5. Pull off the gear position sensor connector.
All vehicles

6. Remove the upper starter motor bolt.

7. Raise the vehicle.
8. Detach the engine undershield.

9. Remove the transmission cover.

10. Detach the starter motor.
• Remove the bolts and detach the ground lead.
• Tie the starter motor to the side.

CAUTION:

Overstretching the flexible pipe can cause damage.
11. Separate the front exhaust pipe.
• Remove the gasket.

12. Remove the clutch housing lower cover.
   Two expanding pins on each side.

13. Pull out the reversing light plug.
14. Remove the clutch housing upper cover.
   One expanding pin on each side.

15. Detach the speedometer cable (if present).

16. Disconnect the vehicle speed sensor (VSS) multiplug (if present).
Vehicles with tachograph
17. Detach the plug of the tachograph vehicle speed sender unit.
All vehicles

NOTE:

Mark the installation position.
18. Slacken the bolts of the driveshaft centre bearing.

NOTE:

Mark the installation position.
19. Detach the driveshaft (four bolts) and tie it up.

20. Remove the clutch housing front cover.

21. Remove the clutch housing intermediate plate bolt.
Vehicles without automatic clutch
22. Detach the clutch cable and withdraw it from the transmission flange.
Vehicles with automatic clutch
23. Detach the cable from the clutch release lever.
   Slacken the lock nut.
Vehicles with automatic clutch
24. Detach the clutch slave cylinder and hook it to one side.
All vehicles
25. Detach the transmission from the rear transmission mounting and detach the front exhaust pipe from the bracket.
26. Support the transmission with the transmission jack.

27. Remove the transmission crossmember and unhook the front exhaust pipe from the rubber insulators.
28. Secure the transmission to the transmission jack with the clamping strap.

29. Remove the left‐hand flange bolts.
1. Flange bolts
2. Engine mounting bracket bolt

30. Remove the right‐hand flange bolts.
1. Flange bolts
2. Engine mounting bracket bolt
31. Carefully separate the transmission assembly from the engine and lower it.
Install
32. General notes.
• Renew all circlips and self‐locking nuts.
• Apply thread locking compound (SDM‐M4G9107‐A) to the threads before inserting the bolts.
• When installing coolant or vent hoses, use the radiator hose clamp remover/installer 24‐003 if necessary.

CAUTION:

Use a new driveshaft pilot bearing.
33. Preparations.
• Clean the inner splines of the clutch disc, the driveshaft splines and the clutch release bearing guide sleeve.
• Thinly apply high‐temperature grease (ESDM‐1C220‐A) to the transmission input shaft, clutch release bearing guide sleeve, driveshaft pilot bearing and the clutch splines.

NOTE:

Check that the guide sleeves are seated correctly.
34. Line up the adaptor plate with the two guide sleeves on the cylinder block.
   Secure the adaptor plate with a little high‐temperature grease (ESD‐M1C220‐A).

35. Locate the transmission assembly in position on the engine with the transmission jack.
36. Screw in the right‐hand flange bolts.
1. Flange bolts
2. Engine mounting bracket bolt

37. Screw in the left‐hand flange bolts.
1. Flange bolts
2. Engine mounting bracket bolt

38. Install the transmission crossmember and hook the front exhaust pipe into the rubber insulators.

39. Attach the transmission to the rear transmission mounting and attach the front exhaust pipe to the bracket.

40. Screw in the clutch housing intermediate plate bolt.

41. Fit the clutch housing front cover.

42. Pass the clutch cable through the transmission flange.
Vehicles with automatic clutch
43. Pass the cable with installation sleeve through the hole in the transmission.
44. Attach the clutch slave cylinder.
Vehicles with automatic clutch
45. Insert the cable into the clutch release lever.
1. Turn the adjustment nut to the stop against the clutch release lever.
2. Secure with a lock nut.
3. Remove the installation sleeve.
Vehicles without automatic clutch
46. Attach the clutch cable.
All vehicles

NOTE:

Mark.
47. Attach the driveshaft.

NOTE:

Mark.
48. Press the driveshaft towards the transmission and tighten the bolts of the driveshaft centre bearing.

49. Connect the VSS multiplug (if present).

50. Attach the speedometer cable (if present).
Vehicles with tachograph
51. Attach the plug of the tachograph vehicle speed sender unit.
All vehicles

CAUTION:

Overstretching the flexible pipe can cause damage.
52. Fit the front exhaust pipe using a new gasket.

53. Fit the clutch housing upper cover.
   One expanding pin on each side.
54. Connect the reversing light plug.

55. Fit the clutch housing lower cover.
   Two expanding pins on each side.

56. Install the starter motor.
   Attach the ground lead and screw in the bolts.

57. Install the transmission cover.

58. Fit the engine undershield.
59. Lower the vehicle.

60. Screw in the upper starter motor bolt.
Vehicles with automatic clutch
61. Push on the gear position sensor connector.
All vehicles
62. Install the gear lever.
1. Screws
2. Noise damping pad
• Fit the rubber gaiter.
Vehicles with automatic clutch
63. Connect the gear lever knob sensor connector.
All vehicles
64. Standard finishing operations.
• Check the routing of the cables and vacuum hoses and secure them with cable ties where necessary.
• Connect the battery negative lead.
• Enter the radio keycode.
• Reprogramme the preset radio stations.
• Reset the clock.
• Carry out a road test to enable the PCM (EEC V) to collect data.
• Check the fluid levels and correct as necessary.
• Fit the engine undershield.
Vehicles with automatic clutch only

NOTE:

The shift lever must be held in 5th gear position.
65. Calibrate the gear position sensor and the slave cylinder position sensor using FDS2000.

Transmission Assembly ‐ Dismantle and Reassemble (Transmission Removed) (16 118 8) > < SpecificationsGeneral Specifications