Gearbox with leading axle (1.8L/1.6L Zetec-E) — installation

Special tool

	Engine support beam 303-290 (21-140)
	Adapter for 303-290 303-290-01 (21-140-01)
	Adapter for 303-290 303-290-02 (21-140-02)
	Adapter for 303-290 303-290-03 (21-140-03)

General equipment: Gearbox jack.

Name	Specification
Transmission fluid	WSD-M2C200-C

Installation

1. General notes:

• Use only new self-locking nuts.

2. Move the transmission to the installation position using the transmission jack and secure it to the engine.

3. Tighten the flange bolts.



4. Tighten the flange bolts.



5. Install the starter and tighten the flange bolts.

• 1. Starter bolt
• 2. Flange bolt

6. Install the roll limiter.



7.

CAUTION: Support the axle shaft. The inner joint should not be deflected at an angle exceeding 18 degrees. The outer joint should not be deflected at an angle exceeding 45 degrees.

CAUTION: To protect the oil seal when installing the front axle shaft, use the installation sleeve (supplied with each new oil seal).

CAUTION: Do not damage the oil seal.

CAUTION: Make sure the snap ring is installed correctly.

NOTE: Secure the tripod joint assembly (continued).

Install the left axle shaft onto the gearbox.



8.

CAUTION: Support the axle shaft. The inner joint should not be deflected at an angle exceeding 18 degrees. The outer joint should not be deflected at an angle exceeding 45 degrees.

CAUTION: To protect the oil seal, use the installation sleeve (supplied with each new oil seal) when installing the front axle shaft.

CAUTION: Do not damage the oil seal.

Install the right axle shaft onto the gearbox.



9.

NOTE: Install a new bracket and new intermediate bearing nuts.

Connect the right axle shaft intermediate bearing mounting bracket.



10. Install the lower control arm ball joints on both sides (right side shown).



11. Install the gear selector and shift cables.

• Install the shift and selector cables onto the bracket by turning the sleeve clockwise.

12. Fill with transmission fluid; the transmission fluid should be filled to a level 5-10 mm below the lower edge of the inspection hole.



13. Close the shift and selector cable cover.



14. Connect the reversing light switch connector.




15. Lower the vehicle.

16. Using special tool 308-290 (21-140), raise the engine and transmission enough to allow installation of the rear engine mount.

17. Install the rear engine mount bracket.



18. Install the rear engine mount.



19. Disconnect the special tools.



20. Tighten the upper flange bolts and starter bolts.

• 1. Flange bolts
• 2. Starter bolts
• Connect the ground wire.

21.

CAUTION: Brake fluid leakage. Observe precautions when handling brake fluid.

Install the high pressure line for the clutch slave cylinder.



22. Insert the clutch hydraulic line into the retaining element.



23. Bleed the clutch hydraulic system. Refer to Section 308-00 for additional information.

24. Connect the vehicle speed sensor (VSS) connector.



25. Install the air filter.

• Insert the air filter with the inlet hose and air chamber and tighten the screws.

26. Install the air filter.

• 1. Install the crankcase ventilation hose.
• 2. Connect the mass air flow sensor (MAF sensor) connector.

27. Tighten the nuts of the left and right suspension struts.

• Lock the piston rod from turning using an Allen key.
• Tighten by hand using a socket wrench.
• Tighten to the specified torque using a torque wrench.

28. Adjust the shift mechanism. For additional information, refer to Section 308-06A / 308-06B / 308-06C.

29. Standard finishing operations:

• Check the vacuum hose and electrical wiring and secure them with clamps.
• Enter the radio key code.
• Reprogram preset radio stations.
• Set the clock.
• Perform a road test to allow the PCM to collect data.
• Recheck the fluid levels and adjust them if necessary.