Gearbox with leading axle (1.8L/1.6L Zetec-E) — removal (Power unit / Mechanical gearbox iB5 / Ford Focus 1 1998-2004)

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)
	Axle puller 308-237 (16-087)

General equipment:

Gearbox jack
Fixing clamp

Removal

1. General notes:

Please mark the radio key code.
Mark the pre-programmed radio stations.

CAUTION: Disconnect the ground cable from the battery.

The position of the engine mounts and engine roll limiters in the description corresponds to the view directed from the gearbox to the engine.
Items whose actions apply to specific variants and not to all vehicles are marked with a special note.
If necessary, remove the clamps and install new ones during assembly.

NOTE: Use an Allen key to prevent the piston rod from turning.

Loosen the left and right suspension strut nuts five turns.

3. Remove the air filter.

1. Disconnect the crankcase ventilation hose.
2. Disconnect the MAF sensor connector.

4. Remove the air filter.

Remove the bolts and remove the collection chamber together with the outlet hose and air filter.

5. Disconnect the vehicle speed sensor (VSS) electrical connector.

6. Remove the clutch hydraulic line from the eye.

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

Disconnect the pressure line from the clutch slave cylinder.

8. Remove the top bolts.

1. Flange bolts
2. Starter bolts
Disconnect the ground wire.

9. Connect special tools.

10. Remove the rear engine mount.

11. Remove the rear engine mount bracket.

12. Lower the engine/gearbox as much as possible. Use the special tool.

13. Raise the vehicle. Refer to Section 100-02 for additional information.

14. Disconnect the reversing light switch connector.

15. Open the shift and selector cable cover.

16. Disconnect the shift and gear selector cables.

Remove the shift and selector cables from the bracket by turning the ring clockwise.

17. Disconnect the lower control arm ball joints on both sides (right side shown).

18. Disconnect the bracket for fastening the intermediate bearing of the right axle shaft.

Discard the mounting bracket and intermediate bearing nuts as they are no longer needed.

19.

CAUTION: Support the axle shaft. The inner joint should not be deflected more than 18 degrees. The outer joint should not be deflected more than 45 degrees.

CAUTION: Do not damage the oil seal.

NOTE: Plug the transmission openings to prevent oil leakage and dirt from entering.

Disconnect the right half shaft from the gearbox and secure it to the side. Collect the oil in a suitable container.

20.

CAUTION: Support the axle shaft. The inner joint should not be deflected more than 18 degrees. The outer joint should not be deflected more than 45 degrees.