Note: Before removal, mark the position of the subframe for correct subsequent installation.
Warning: The transmission must be securely supported on a jack during removal and installation.
An assistant is required to perform this operation.
When removing the gearbox, the entire subframe is removed, as well as the wheel drive shafts.
When removing, you will need a device to lift the engine.
To remove the gearbox, perform the following operations:
- Disconnect the battery. Cable ties should be cut and replaced accordingly during installation;
Fig. 22. Fastening of air intake pipes: 1 — fastening bolts, 2 — plug, 3 — plug block, 4 — clamp, 5 — low-pressure hose
- unscrew the four screws 1 (see Fig. 22) of the fastening;
- remove plug 2 from the air flow meter and remove clamps 3 of the hose on the same side;
- remove the multi-pin plug 4 of the intake air sensor;
- remove low pressure hose 5;
- remove the air intake pipe;
- disconnect the ventilation hose between the filter and the cylinder head cover;
- unhook the rubber ring on the right, lift and remove the air filter from the mount;
Fig. 168. Gearbox wiring location: 1 - negative wire; 2, 3 - multi-pin plugs
- disconnect the wiring from the gearbox (Fig. 168);
Fig. 169. Fastening the gearbox cable: 1 - spring clamp; 2 - screws
- disconnect the shift cable (Fig. 169). To do this, remove the spring clip 1 from the cable on the automatic transmission control lever and unscrew the screws 2;
- loosen the wheel nuts;
- place the car on supports in front;
- remove both front wheels;
- on the engine pulley side, unscrew the fastening elements of the protective cover in the wheel well;
- place the car on supports on the right and left;
- disconnect the anti-roll bar linkage and lever system from the chassis shock absorber strut and the steering trapezoid linkage joint from the pitman arm;
- disconnect the ball joint from the lower surface of the steering knuckle on the left and right;
- unscrew the mudguard under the front of the car and drain the coolant from the cooling system;
- remove the multi-pin plug from the lambda probe and disconnect the cable clamp;
- Disconnect the low pressure hose from the Air-Pulse system filter;
- remove the exhaust system parts;
- unscrew the steering and the rear stop from turning the engine from the subframe. The steering screws are difficult to reach. The Ford service center uses a specially bent ring spanner for this purpose;
- release the fasteners and free the rear stop console from the gearbox;
Fig. 170. Location of the front stop mounting screw
- unscrew the middle screw, shown in Fig. 170, from the front engine stop against turning;
- unscrew the Air-Pulse system filter from the mounting on the stop against rotation;
- unscrew the radiator mounting bracket;
Fig. 167. Location of guide pins
- unscrew the four subframe mounting screws (see Fig. 167) and lower it. Before removing, mark the position of the subframe in the mount;
Fig. 171. Location of the rear stop mounting screw
- unscrew the rear stop (Fig. 171) of the gearbox;
- disconnect the oil line on the rear side between the gearbox and the oil cooler;
Fig. 172. Removing the left drive shaft: 1 — oil line; 2 - installed lever
- to remove the drive shaft, install the tire mounting lever, as shown in Fig. 172, behind the constant velocity joint and jerk the joint out;
- secure the shaft so that the joint cannot bend;
- remove the wheel drive shaft;
- secure the shaft to the chassis without creating a large angle in the constant velocity joint;
- disconnect the oil line at the front between the gearbox and the oil cooler;
- unscrew the two screws on the bottom of the gearbox and remove the cover. This will expose the ring gear and torque converter. Unscrew the screws one by one and turn the crankshaft until all the screws appear in turn at the bottom of the gearbox;
- disconnect both multi-pin plugs from the thermostat housing, disconnect the hoses and remove the thermostat housing;
- disconnect the oil line at the front between the gearbox and the oil cooler;
- place a car jack under the engine/drive (with a wooden spacer between the jack head and the engine/drive) and lift the power unit;
- unscrew the screws securing the gearbox to the engine at the top;
- unscrew the right engine mount;
- remove the bracket;
- on the opposite side, unscrew the self-locking nuts of the left engine mount from the gearbox;
- lower the gearbox so that it is at the same height as the left longitudinal beam, and raise the car again;
- unscrew the remaining screws securing the gearbox to the engine and the remaining screws securing the starter;
- check that the gearbox is securely mounted on the jack and carefully remove it from the engine.
When installing, replace all self-locking nuts and cut cable ties with new ones.
To install the gearbox, perform the following operations:
Fig. 173. Place of measurement of distance "A"
- insert the torque converter into the gearbox. To ensure its proper fit, measure the distance from the mating surface of the gearbox to the torque converter journal. To do this, place a ruler on the surface and measure with a depth gauge (Fig. 173). This measurement should be 10 mm. If the measurement is smaller, the torque converter is not properly engaged with the oil pump;
- place the gearbox on a jack, ask an assistant to hold it and press it against the engine flange;
Fig. 174. Fastening the drive disk to the torque converter
- at the bottom of the gearbox, turn the crankshaft and torque converter so that the first screw can be inserted (Fig. 174). Lightly tighten the screw and turn the crankshaft so that the remaining screws can be screwed in;
- tighten all screws evenly to a torque of 36 Nm;
- screw in the gearbox mounting screws to the engine and slowly tighten to a torque of 40 Nm;
- tighten the lower starter mounting screws to 48 Nm;
- lower the car onto its wheels;
Fig. 34. Device for lifting the engine and drive when hanging the engine
- install the lifting device (see Fig. 34);
- screw the left engine mount onto the gearbox without tightening the nuts;
- install the right engine mount. Do not tighten the nuts;
- install the drive shaft of the wheels on the left into the gearbox;
- Insert a new snap ring into the groove of the shaft before pushing the end of the shaft into the gearbox. When installing the shaft, do not damage the sealing ring;
- on the rear side, screw the oil line between the gearbox and the oil cooler and tighten to 23 Nm;
- secure the wiring with a clamp;
- secure the wiring on the front side;
- push the right drive shaft into the gearbox, screw in the thrust bearing and tighten both screws 1 to a torque of 27 Nm;
- secure the heat shield 2;
- install the rear engine stop;
- tighten the middle screw by hand;
- install the subframe as described when installing the engine;
- carry out further assembly in the reverse order of removal.
Tightening torques for connections, Nm:
- screws (see Fig. 170 and 171) 120
- mount to exhaust manifold 40
- wheel mounting nuts 85