Removing and installing manual transmission (Mondeo 1 and 2)

Note: Read the entire procedure, especially the instructions regarding lifting equipment. Depending on your means, you may want to remove the powerhead first, then use a workbench to separate the engine from the transmission (Chapter 2).

Removal

1. Disconnect the negative battery cable (chapter 5A). For better access, the battery can be removed.

2. If necessary, remove the hood (Chapter 11).

3. Secure the radiator in the working position by inserting cotter pins into the holes in the upper support pins (see Fig. 7.3). This is necessary to hold the radiator when removing the subframe.



4. Remove the air flow meter and intake air duct (chapter 4A). On models with V-6 engines, remove the cooling system pump pulley cover.

5. Remove the air cleaner assembly (chapter 4A).

6. Disconnect the wiring from the reverse light switch on the transmission (see Fig. 7.6).



7. Remove the bolt and wire harness bracket from the top of the transmission (See Fig. 7.7).





8. Disconnect the ground wire connecting the transmission to the body. On V6 models, disconnect the accelerator and cruise control cables. On these models, disconnect the wiring from the power steering pressure sensor. Then release the power steering line from the clamp on the bracket on the right side of the engine and move the line to the side.

9. Disconnect the clutch cable or line from the transmission (chapter 6).

10. Remove the three upper transmission-to-engine mounting bolts. Also remove the ground wire bolt located under the exhaust manifold (see Fig. 7.10).



11. On models with 4-cylinder engines, unscrew the upper starter mounting bolt, taking into account that the ground wire is installed on it (see Fig. 7.11). On models with V-shaped 6-cylinder engines, remove the starter (chapter 5A).





12. Apply the parking brake, lift the front end and place it on supports. Remove the front wheels.

13. Remove the front lower cover from the lower part of the radiator. To do this, release it from the clips and unscrew the mounting bolts (see Fig. 7.13).



14. Remove the wheel arch liner from the right side of the vehicle (Chapter 11).

15. Loosen the bolts and remove the accessory drive cover.

16. Disconnect the anti-roll bar connecting link from the suspension strut. To do this, working alternately on each side of the car, unscrew the nut of each link. Note that the brake hose bracket is attached to the connecting link stud.

17. Remove the cotter pins and then the nuts securing each tie rod end to the steering knuckle. Release the ball joints from the steering knuckles using a ball joint puller.



18. Working alternately from each side of the car and taking into account which side the front lower arm ball joint clamp bolt is inserted, unscrew the bolt. Remove it from the knuckle. Press the ball joint away from the steering knuckle. If this is difficult to do, press the joint apart with a power screwdriver or a crowbar. Do not damage the ball joint seal.

19. Disconnect the cooling system fan electrical connector located on the subframe behind the radiator. Unfasten the connector plug from the bracket.

20. Disconnect the oxygen sensor wiring harness electrical connector. Then unclip the wiring harness from the rear engine mount.

21. Disconnect the vacuum hose from the fuel afterburning system filter.

22. Remove the entire exhaust system (chapter 4).

Models produced before 1997 with a lever-type gear shift

23. Remove the bolt securing the gear shift lever mechanism to the selector shaft on the rear side of the transmission (see Fig. 7.23).



24. Mark the position of the rear section of the linkage relative to the front section. Loosen the clamp bolt. Disconnect the linkage from the selector shaft at the rear of the transmission. Separate the front section from the rear section (see Fig. 7.24).





25. Remove the bolt and disconnect the linkage support rod from the bracket on the rear of the transmission (see Fig. 7.25).



26. Remove the heat-insulating casing of the lever mechanism from the bottom. To do this, unscrew the nuts. Unscrew the bolts of the rear support of the lever mechanism, tilt the mechanism back and tie it to the body (see Fig. 7.26, a-c).

Models produced since 1997 with cable-operated gear shifting

27. Disconnect both cables from the transmission (paragraph 3).

All models

28. On models with air conditioning, remove the bolts securing the evaporator to the subframe and tie the evaporator down.

29. Remove the steering gear mounting bolts from the subframe. It is difficult to reach them with a regular wrench. It is advisable to use a Ford elbow adapter (Chapter 10).

30. Unscrew the central bolt from the rear support of the power unit (roll limiter). Then unscrew the support bolts from the subframe (see Fig. 7.30, a, b).



31. On lever-driven models, loosen the nut and bolt and remove the support rod bracket from the rear of the transmission (see Fig. 7.31,a,b).



32. Loosen the nuts and bolts and remove the power unit rear support bracket from the transmission (see Fig. 7.32, a, b).





33. Remove the central bolt from the front engine mount. Disconnect the fuel afterburning system filter from the bracket located on the mount (see Fig. 7.33).



34. With the help of an assistant, support the subframe and unscrew the bolts securing the hydraulic steering system radiator pipes to the subframe. Then unscrew the subframe bolts and lower it to the ground (see Fig. 7.34, a-c).







35. Place a container under the transmission. Then unscrew the oil drain plug (see Fig. 7.35). Finally, install and tighten the plug.



36. Remove the bolts securing the right input shaft center bearing to the cylinder block. Remove the heat-insulating casing. Then pull the right strut so that the intermediate shaft comes out of the transmission differential. Be prepared to eliminate oil leaks.

37. Support the right drive shaft so that the inner joint does not rotate more than 18° (otherwise it may be damaged).

38. Insert a pry bar between the left drive shaft inner joint and the transmission housing (use a thin piece of wood between the housing and the pry bar). Then pry the joint away from the differential. If necessary, tap the pry bar with the palm of your hand. Be careful not to damage adjacent components, and be prepared to clean up any oil leaks. Once the right drive shaft is removed, you can free the left drive shaft by inserting a fork-end drift from the right side. Be careful not to damage the differential gears.

39. Support the left drive shaft so that the inner joint does not rotate more than 18° (otherwise it may be damaged).

40. Disconnect the engine speed sensor wiring connector.

41. On early models, loosen the cable nut and disconnect the speedometer cable from the top of the vehicle speed sensor. Hold the sensor with a wrench while loosening the nut.

42. If necessary, the vehicle can be lowered to the ground at this point to attach the hoist to the engine. If the engine is supported on a rod resting on the engine compartment, the vehicle can remain in the raised position.

43. Attach the hoist by securing the clamp to the engine's diagonally located lifting eyes and lift the power unit (see Fig. 7.43).



44. Unscrew the nuts of the right engine support bracket. Note that if this support is hydraulic (chapter 2A paragraph 22), then it should not deviate from the vertical by more than 5°.

45. Loosen the nuts and remove the left support of the power unit from the transmission.

46. On models with air conditioning, lower the engine until the compressor is below the right crossmember.

47. On models without air conditioning, lower the transmission until it is against the opening located on the left side of the engine compartment.

48. Support the transmission with a jack. Secure it to the jack with chains or a suitable support.

49. On models with 4-cylinder engines, remove the remaining starter bolts.

50. Remove the lower transmission-to-engine mounting bolts. Also remove the lower cover-to-transmission mounting bolts.

51. With the help of an assistant, separate the transmission from the engine, being careful not to tilt it and so that the friction disk of the clutch does not bear the weight of the transmission. After removing the transmission, remove the lower cover installed between the transmission and the engine (see Fig. 7.51). Lower the transmission to the ground.



52. Now you can inspect the clutch components (chapter 6) and replace if necessary.

Installation

53. Install the clutch components (chapter 6), if they were removed.

54. Raise the transmission, supported by the jack, to the operating position, and then carefully mate it to the rear of the engine so that the input shaft engages the splines of the clutch disc. Do not use excessive force. If the input shaft engages with difficulty, rotate the transmission to a horizontal position and/or rotate the transmission horizontally. If this does not help, check that the clutch disc is correctly centered (chapter 6).

55. Insert the lower transmission-to-engine mounting bolts and tighten them lightly.

56. On 4-cylinder models, insert and tighten the starter bolts, taking into account that one of them secures the ground wire. On V6 models, install the starter (chapter 5A).
57. Raise the transmission to its operating position.
58. Install the left power unit support and tighten its nuts.
59. Install the right engine mount bracket and tighten its nuts.
60. Raise the front end and place it on supports if it was lowered to the ground.
61. Install the speedometer cable to the vehicle speed sensor and tighten the cable nut.
62. Connect the wiring to the speed sensor.
63. Insert the left drive shaft into the transmission until the inner elastic ring of its fixation snaps into place.
64. Install the right drive shaft and intermediate shaft and tighten the bolts.
65. Install and adjust the subframe (chapter 2B paragraph 4). Tighten the bolts to the specified torque.

66. Install the fuel afterburning filter. Tighten the front engine mount center bolt.

67. Install the rear engine mount bracket and tighten the bolts.

68. Install the transmission support rod and bracket and tighten the bolts and nut.

69. Install the rear engine mount onto the subframe and tighten the bolts.

70. Install the steering gear on the subframe and tighten the bolts.

71. On models with air conditioning, install the evaporator to the subframe and tighten the bolts.

72. Install the shift mechanism and heat-insulating casing (paragraph 3).

73. Install the transmission shift support rod to the rear of the transmission and tighten the bolt. Adjust the mechanism (paragraph 2).

74. Install the exhaust system (chapter 4).

75. Connect the vacuum hose to the fuel afterburning system filter.

76. Connect the oxygen sensor wiring.

77. Connect and secure the cooling system fan electrical connector.

78. Install the ball joint of each front lower control arm to the steering knuckle (Chapter 10).

79. Install each tie rod end to the steering knuckle (Chapter 10).

80. Install the anti-roll bar connecting links to the suspension struts and tighten the nuts.

81. Install the accessory drive cover and wheel arch liner.

82. Install the lower front cover under the radiator.

83. Install the wheels and lower the vehicle to the ground.

84. Install the upper transmission-to-engine mounting bolts.

85. Connect the clutch cable or pipe (chapter 6). On V6 models, connect the power steering line. Reattach the line to the bracket on the right side of the engine. The ground wire should be secured with one of the nuts on this bracket. Connect the wiring to the power steering pressure sensor.

86. Connect the ground wire to the transmission and body.

87. Install the wiring harness bracket to the top of the transmission.

88. Connect the wiring to the reverse light switch.

89. Fully tighten all transmission mounting bolts.

90. Install the air cleaner assembly, air flow meter and air intake duct (chapter 4A).

91. Remove the cotter pins securing the radiator.

92. Install the hood if it was removed.

93. Install the battery if it was removed and connect its cables.

94. Fill the transmission with oil and check its level (chapter 1).

95. Finally, check and make sure that you have connected everything that is necessary and that the bolts are fully tightened.

96. Test drive the vehicle, checking the transmission operation. Then check for oil leaks.