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In-vehicle Repair|Disassembly > < Crankshaft Rear Seal

Transit 2000.5 (01.2000-05.2006)

Engine - 2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel - Engine Transit 2000.5 (01/2000-05/2006)
Removal

Special Tool(s)

Remover/Installer, Cooling Hose Clamp

303-397 (24-003)

Remover, Halfshaft

308-192 (16-057)
General Equipment
Securing straps
Two leg puller
Workshop table

Removal

All vehicles
WARNING:
WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may ignite. Failure to follow these instructions may result in personal injury.
  1. Remove the front wheels and tires.
    For additional information, refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).
  1. Remove the radiator grille opening panel.
    For additional information, refer to: Radiator Grille Opening Panel (501-02 Front End Body Panels, Removal and Installation).
Vehicles with air conditioning
  1. Drain the air conditioning system.
    For additional information, refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00 Climate Control System - General Information, General Procedures).
All vehicles
  1. Drain the cooling system.
    For additional information, refer to: Cooling System Draining, Filling and Bleeding (303-03 Engine Cooling, General Procedures).

  1. Remove the engine oil filler pipe.

  1. Remove the intake air resonator retaining bolts.

  1. Remove the air cleaner outlet pipe and intake air resonator assembly.
Vehicles with common rail fuel injection
  1. Remove the engine upper cover.

  1. Disconnect the vacuum hoses from the control unit.

  1. Disconnect the injection control unit (ICU) electrical connector.
All vehicles
  1. Remove the cooling fan motor and shroud.
    For additional information, refer to: Cooling Fan Motor and Shroud - 2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel, Vehicles With: Air Conditioning (303-03 Engine Cooling, Removal and Installation) /
    Cooling Fan Motor and Shroud - 2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel, Vehicles Without: Air Conditioning (303-03 Engine Cooling, Removal and Installation).

  1. Using the special tool, disconnect the coolant hoses from the water pump.

  1. Disconnect the coolant hoses from the thermostat housing.
    • Disconnect the degas hose.
  1. Remove the accessory drive belt.
    For additional information, refer to: Accessory Drive Belt - 2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel (303-05 Accessory Drive, Removal and Installation).

  1. Using the special tool, disconnect the radiator upper hose.

  1. Using the special tool, disconnect the coolant expansion tank hose and the radiator lower hose.

  1. Disconnect the engine wiring harness electrical connector.

  1. Remove the jump start point cover.

  1. Disconnect the battery to starter motor solenoid cable from the jump start point.
  1. Disconnect the fuel supply and return line quick release couplings.
    For additional information, refer to: Fuel System Service Precautions (310-00B Fuel System - General Information - Liquified Petroleum Gas (LPG), General Procedures).

  1. Disconnect the coolant hoses and the vacuum hoses from the heater core.
Vehicles with auxiliary heating
  1. Disconnect the heater control valve electrical connector.

  1. Using the special tool, disconnect the heater hoses from the auxiliary heater core housing.
All vehicles
  1. Detach the gearshift cables from the transaxle.
    1. Press the tabs together to release the locks.
    1. Pull the locking pins and detach the abutment sleeves.

  1. CAUTION:
    CAUTION:If brake fluid is spilt on the paintwork, the affected area must be immediately washed down with cold water.
    Disconnect the clutch slave cylinder supply line from the transaxle.

  1. Disconnect the power steering line from the power steering pump.
    • Discard the O-ring seal.

  1. Disconnect the reversing lamp switch electrical connector.
  1. Remove the catalytic converter.
    For additional information, refer to: Catalytic Converter - 2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel/2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel (309-00 Exhaust System, Removal and Installation).

  1. Disconnect the charge air cooler intake pipe from the charge air cooler.

  1. Disconnect the charge air cooler outlet pipe from the charge air cooler.

  1. Disconnect the temperature and manifold absolute pressure (T-MAP) sensor electrical connector.

  1. Disconnect the horn electrical connector.

  1. Remove the radiator support bracket lower bolt.

  1. Remove the radiator support bracket right-hand retaining bolts.

  1. Remove the radiator support bracket and the radiator.

  1. Loosen the lower arm ball joint retaining nuts.

  1. CAUTION:
    CAUTION:Protect the ball joint seal using a soft cloth to prevent damage.
    Using a suitable two leg puller, detach the lower arms from the wheel knuckles.
    1. Use a soft faced hammer to strike the lower arm.
    1. Remove and discard the retaining nut.
    1. Remove the heat shield.

  1. CAUTION:
    CAUTION:Leave the tie-rod end retaining nut in place to protect the ball joint stud.
    Loosen the left-hand tie-rod end retaining nut.

  1. CAUTION:
    CAUTION:Protect the ball joint seal using a soft cloth to prevent damage.
    Using a suitable two leg puller, detach the left-hand tie-rod end from the wheel knuckle.
    1. Release the tie-rod end.
    1. Remove and discard the retaining nut.

  1. CAUTION:
    CAUTION:Support the halfshaft. The inner joint must not be bent more than 21 degrees. The outer joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Do not damage the halfshaft oil seal.
    NOTE:
    NOTE:Plug the transaxle to prevent oil loss and dirt ingress.
    Detach the right-hand halfshaft from the transaxle and secure it to one side.
    • Remove and discard the center bearing cap and locknuts.
    • Allow the oil to drain into a suitable container.

  1. CAUTION:
    CAUTION:Support the halfshaft. The inner joint must not be bent more than 21 degrees. The outer joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Do not damage the halfshaft oil seal.
    NOTE:
    NOTE:Plug the transaxle to prevent oil loss and dirt ingress.
    Using the special tool, detach the left-hand halfshaft from the transaxle and secure it to one side.
    • Allow the oil to drain into a suitable container.
    • Discard the snap ring.

  1. Remove the engine support insulator.
    • Discard the engine support insulator to transaxle housing bolt.
  1. Position a suitable workshop table under the engine and transaxle assembly.
  1. WARNING:
    WARNING:Support the engine and transaxle assembly on wooden blocks and secure it with suitable securing straps.
    Carefully lower the vehicle until the engine and transaxle assembly is supported by the workshop table.

Vehicles built up to 07/2003
  1. Remove the engine rear mount.

  1. Remove the engine front mount.
    • Discard the engine front mount to engine bracket bolts.
Vehicles built 07/2003 onwards
  1. Remove the engine rear mount.

  1. Remove the engine front mount.
    • Discard the engine front mount to engine bracket bolts.
All vehicles
  1. Pull the workshop table with the transaxle and engine assembly forwards.

  1. Remove the transaxle retaining bolts from the left-hand side.

  1. Remove the transaxle retaining bolts from the right-hand side.
  1. CAUTION:
    CAUTION:Do not tilt the transaxle during removal.
    Remove the transaxle.

In-vehicle Repair|Disassembly > < Crankshaft Rear Seal