Gearbox with leading axle (1.6L Zetec-SE/1.4L) — installation

Special tool

	Engine support beam 303-290 (21-140)
	Adapter for 303-290 303-290-01 (21-140-01)
	Adapter for 303-290 303-290-03 (21-140-03)
	Adapter for 303-290 303-290-05 (21-140-05)
	Adapter for 303-290 303-290-06 (21-140-06)

General equipment:

• Gearbox jack
• Fixing clamp

Name	Specification
Transmission fluid	WSD-M2C200-C

Installation

1. General notes:

• Use only new self-locking nuts.

2. Secure the gearbox using the locking clamp and move it to the installation position using the gearbox jack.



3. Tighten the flange bolts.

• Install the bracket for the power steering high pressure line.

4. Tighten the flange bolts.




5. Remove the wooden block.



6. Lower the vehicle.

7. Tighten the upper flange bolts.



8. Install the rear engine mount bracket.



9. Install the rear engine mount connection and the high pressure line bracket of the working cylinder.

• 1. Bracket of high pressure line of the working cylinder
• 2. Communication

10. Using the special tool, raise the engine and gearbox enough to allow the rear engine mount to be installed.

11. Install the rear engine mount.



12. Disconnect the special tools.



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


14. Install the drive belt cover.



15.

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.



16.

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: Do not damage the oil seal.

Install the right axle shaft onto the gearbox.



17.

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

Connect the right axle shaft intermediate bearing mounting bracket.



18. Install the roll limiter.



19. Install the lower control arm ball joints on both sides.



20. Tighten the exhaust pipe mounting elements.



21. Install the starter. Connect the ground wire.



22. Install the gear selector and shift cables.

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

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



24. Close the shift and selector cable cover.



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



26. Connect the reversing light switch connector.



27. Lower the vehicle.

28.

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

Connect the high pressure line of the clutch slave cylinder.

• Insert the high pressure line of the clutch slave cylinder into the bracket.

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

30. Install the intake manifold.



31. Install the air filter.

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

32. Install the battery tray.

• 1. Connect the wiring harness.
• 2. Screw in the bolts.
• 3. Connect and secure the connector.

33. Install the battery and connect the wires to it.

34. 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.

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

36. 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.