Gearbox with driving axle (1.8L diesel) — removal (Power unit / Mechanical gearbox MTX-75 / Ford Focus 1 1998-2004)

Special tool

	Ball joint puller 211-020 (13-006)
	Engine Support Beam 303-290A (21-140A)
	Adapter for 303-290A (21-140) 303-290-01 (21-140-01)
	Adapter for 303-290A (21-140) 303-290-02 (21-140-02)
	Adapter for 303-290A (21-140) 303-290-03A (21-140-03A)
	Adapter for 303-290A (21-140) 303-290-06 (21-140-06)
	Drive axle half shaft puller 308-192 (16-057)

General equipment:

Gearbox jack
Technological plugs
Fixing clamp

Removal

All cars

1. General notes:

Items whose actions apply to specific variants and not to all vehicles are marked with a special note.

2. Remove the battery. For more information, refer to Section 414-01.

3. Remove the battery tray.

1. Release and disconnect the plug connector.
2. Remove the bolts.
3. Release the wiring harness.

4. Loosen the suspension strut nuts five turns on both sides.

5. Disconnect the intercooler air duct.

6. Disconnect the intake air temperature (IAT) sensor connector.

7. Disconnect the intercooler.

8. Remove the air filter housing.

1. Release the hose clamp.
2. Disconnect the plug connector.
3. Disconnect the vacuum hose.

9. Remove the air intake pipe.

10. Disconnect the plug connector and disconnect the glow plug wires.

1. Generator connector
2. High pressure fuel pump connector
3. Glow plug wire

11. Disconnect the crankcase ventilation oil separator.

12. Release the wiring harness and disconnect the engine cooling fan connector.

13. Disconnect the power steering high pressure line bracket.

14. Disconnect the plug connectors.

Vehicle Speed Sensor (VSS)
Gearbox Wiring Harness
Reverse light switch

15. Remove the fan.

Release the clamps on both sides and pull the fan down and out.

16. Disconnect the catalytic converter from the exhaust manifold (four nuts).

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

18. Remove the front left wheel.

19. Disconnect the drive belt cover.

Remove the engine guard (nine bolts) (if equipped).

20. Disconnect the tie rod end nut from the left wheel steering knuckle.

21. Disconnect the steering rod joint from the left steering knuckle.

Press the tie rod end out of the steering knuckle using a special tool.

22.

CAUTION: Do not damage the case.

Disconnect both lower control arms and the left stabilizer link (left side shown).

Remove the heat shield.

23. Disconnect the starter and tie it up.

24. Disconnect the intermediate shaft bearing cover of the right axle shaft.

Discard the nuts and bearing cap.

25.

CAUTION: The inner hinge should not be adjusted more than 18 degrees, and the outer hinge should not be adjusted more than 45 degrees.

NOTE: Plug the hole in the gearbox using a service plug.

Remove the intermediate shaft with the axle shaft from the gearbox and tie them up.

26.

CAUTION: The inner hinge should not be adjusted more than 18 degrees, and the outer hinge should not be adjusted more than 45 degrees.

NOTE: Plug the hole in the gearbox using a service plug.

NOTE: Discard the retaining ring as it is no longer needed.

Disconnect the left axle shaft from the gearbox.

Disconnect the axle shaft from the gearbox using a special tool.
Remove the axle shaft from the gearbox and tie it down.

27. Remove the catalytic converter with the flexible exhaust pipe. Refer to Section 309-00 for additional information.

28. Remove the roll limiter.

Cars manufactured up to 10.2001.

29. Disconnect the gear shift cables from the gear shift lever.

1. Disconnect the gear shift cable from the gear shift lever.
2. Disconnect the gear selector cable from the gear shift lever.

30. Disconnect the gear shift cables from the bracket.

1. Release the support bracket by turning it counterclockwise and disconnect the gear shift cable.
2. Release the support bracket by turning it counterclockwise and disconnect the gear selector cable.

Cars manufactured since 10.2001.

31.

NOTE: Press the shift cable lock buttons.

Disconnect the shift cables from the transmission.

1. Disconnect the gear shift cable from the gear shift lever.
2. Disconnect the gear selector cable from the selector lever.

32. Disconnect the gear shift cables from the bracket.

1. Release the support bracket by turning it counterclockwise and disconnect the gear shift cable.
2. Release the support bracket by turning it counterclockwise and disconnect the gear selector cable.

All cars

33. Lower the car.

34.

WARNING: Brake fluid leakage. Avoid contact with skin and eyes. If brake fluid comes into contact with skin or eyes, rinse the affected area immediately with water.

CAUTION: If brake fluid comes into contact with paintwork, immediately wash the affected areas with water.

Disconnect the high pressure line from the clutch slave cylinder.

Remove the clamp.
Remove the high pressure line from the bracket and tie it down.

35. Disconnect the coolant line from the bracket.

Remove the transmission wiring harness connector bracket.
Secure the coolant line.

36. Remove the upper flange bolts.

37. Connect special tools.

38. Disconnect the rear engine mount.

39. Lower the engine and gearbox assembly slightly using special tool 303-290A.

40. Remove the rear engine mount bracket.

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

42. Move the engine and gearbox assembly forward and insert a wooden block approximately 350 mm long between the engine and the subframe.