Removing and installing the gearbox (Mondeo 1)

The gearbox can be removed without removing the engine for repair or replacement, or if the clutch needs to be removed. Since it is not recommended to repair the gearbox and wheel drive at home, only the removal of the unit as a whole is described below. The car is equipped with a manual gearbox MTX-75 or automatic gearbox CD4E manufactured by FORD.

The gearbox is removed downwards. A suitable lifting platform or inspection pit with a lift and wooden pads is required for removal. The automatic transmission is removed in much the same way as the manual transmission, pay attention to special instructions.

Removal

Disconnect the negative (-) cable from the battery.

Warning! This will erase data in electronic memory devices, such as the engine fault memory device or the radio code. Please read the section carefully "Removing and installing the battery", before disconnecting it.

Fix the radiator at the top, as the lower mount is removable. To fix, insert a wire into the upper mount of the radiator.



Loosen the shock absorber strut nuts by turning them five turns, do not turn the nuts completely. Hold the shock absorber rod with an Allen key when turning.



Remove the air filter and intake pipe, see p. 5.6.



Disconnect the ground wire "1" on the gearbox.

Disconnect plug "2" of the reversing light switch.



Disconnect the clutch cable from lever "1", while pressing the lever slightly with your hand in the direction of the cable.

Disconnect the cable from the holder "2" and put it aside.



Remove the three upper flange bolts "1" engine/gearbox.



Remove bolts "2" of the upper starter mount and battery ground wire.

Remove the right and left driveshaft axles, see item 11.8.



Unscrew the bolts of the wheel arch cover. Unscrew the fastening "2" of the V-belt cover and remove it.



Unscrew the union nut "A" of the speedometer drive shaft, remove the shaft. Disconnect the connection of the plug of the wire "B" of the speedometer sensor.



Remove the lower radiator shroud.

Automatic transmission

Disconnect the oil inlet and outlet lines from the transmission oil cooler and close the holes with suitable plugs. Catch any leaking oil with a thick rag.

Caution: Do not allow contaminants to enter the oil circuit, as this will lead to a malfunction.

Disconnect the cable "1" of the mode selection lever. Unscrew the counter support mounting bolts.



Unscrew the two flywheel cover mounting bolts and remove the cover. Unscrew the four torque converter mounting nuts through the opening, for which turn the crankshaft each time by 1/4 turn. To turn the engine, install the head on the central bolt of the V-belt pulley on the crankshaft.



Remove the thermostat housing, see p. 3.5.

Disconnect the two multi-pin control plugs on the automatic transmission.



Disconnect plug "1" of the Lambda sensor and disconnect the plug from the plate.

Disconnect the vacuum hose "2" from the pulse air system filter.

Disconnect the front exhaust pipe from the exhaust manifold. Disconnect the exhaust system from all suspensions and remove the system as a whole, see item 8.

Set the gear shift lever to neutral position, gear disengaged.



Disconnect the shift rod from the gearbox shift shaft by loosening the clamp bolt "1" and pulling off the shift rod "2".

Remove the bolts "3" of the gear shift rod stabilizer.



Unscrew the fastening of the heat-insulating shield of the shift levers. Turn the shift levers back and secure them with wire to the car structure.





Remove the bolts, remove the air conditioner dryer (where installed) and secure it with wire to the vehicle structure.



Remove the steering gear mounting bolts on the subframe.

Remove the central bolt "2" on the engine jet support. Remove the bolts "3" and remove the bracket from the subframe.

Remove the bolts securing the engine jet support bracket to the gearbox.



Remove the central bolt of the front engine mount.





Support the subframe with a lift. Unscrew the mounting bolts, lower and remove the subframe.



Support the gearbox with a lift. Use wooden blocks to avoid damage.

Attach the engine lifting device to the engine transport plate and lift it slightly with the overhead crane.

Right engine mount

Left engine mount

Unscrew both engine mount arrow nuts.



Lower the power unit until the gearbox is level with the left side member. On vehicles with air conditioning, lower the engine until the air conditioning compressor is below the right side member.

Lightly support the box on the lift.



Remove the two bolts "1" securing the starter and the two lower flange bolts "2" of the gearbox.

Lift the box with your hands, use a crowbar to separate it from the engine and then lower it down.

Installation

Automatic transmission: Before installation, apply ruler "1" to the transmission flange and measure the installation size of the torque converter. It should be at least 10 mm. Do not change the installation size of the converter during installation. Pay attention to the correct location of the intermediate plate.

Warning! Insufficient installation dimension of the torque converter leads to damage to the box and drive disk. The converter will not connect optimally to the oil pump.

Before installing the gearbox, check the clutch and release bearing, see item 9.

Use new self-locking nuts for engine mounts. Replace all removed rings.

Clean and lubricate the gearbox input shaft splines with a thin layer of Moly-Spray grease.

Caution! Do not apply too much grease, as it may get onto the working surfaces of the clutch during operation and impair its functioning.

Raise the gearbox and engage the clutch horizontally. If the shaft splines do not engage the splines of the clutch driven disk, turn the drive shaft or engine crankshaft the required amount.

Move the gearbox until the clutch housing holes fit into the guide bushings.

Tighten the two lower gearbox flange bolts to 40 Nm. Secure the starter with two bolts, tightening the bolts to 50 Nm.

Caution: Do not tighten the gearbox to the engine by tightening the bolts.

Direct the power unit from below into the engine compartment, making sure that the engine mounts are positioned correctly.

Screw on the engine mount nuts, but do not tighten them all the way.

Install and secure the speedometer drive shaft, connect the speedometer sensor plug.

Install the right and left axle shafts, see item 11.8.



Install the subframe, screw in the bolts without tightening. Correct the position of the subframe with a suitable rod, inserting it into the hole in the subframe and the bottom. Tighten the four subframe mounting bolts in this position with a torque of 110-150 Nm. Remove the rod.

Correct the position of the power unit by rocking it, it should move freely on the front jet support.

Tighten the left and right engine mount nuts to 90 Nm.

Disconnect the crane beam and remove the lift.

Secure the rear engine mount with three bolts to the subframe to a torque of 50 Nm. Tighten the center bolt of the mount to a torque of 120 Nm, without pushing the engine to the side. The mount must not be under tension.

Tighten the steering gear mounting bolts to 130 Nm

Tighten the front engine mount center bolt to 120 Nm.

Secure the air conditioner dehumidifier where required.

Install the shift lever heat shield.



Install the shift levers. Tighten bolt "1" to 55 Nm, bolt "2" to 25 Nm. Do not tighten the clamp bolt, it should be tightened only after adjusting the shift.

Place the gear shift lever in neutral.

Install the exhaust system assembly, see item 8.

Connect the Lambda sensor plug and attach the plug to the plate.

Connect the vacuum hose of the pulse air filter.

Install the lower radiator shroud.

Install the V-belt pulley cover.



Fit and tighten to 40 Nm the three upper engine/gearbox flange bolts.

Tighten and tighten to 50 Nm the bolts "2" of the upper starter mount and the battery ground wire.

Remove the retaining wire from the upper radiator support.

Attach the cable and adjust the clutch, see p. 9.3.

Secure the engine/transmission ground wire to the transmission.

Connect the reversing light switch plug.



Tighten the nuts of the right and left shock absorber struts to a torque of 50 Nm, holding the shock absorber rod from turning.

Install the air filter and intake pipe, see p. 5.6.

Check the placement of the vacuum hose and wires, secure with holders if necessary.

Adjust the gear shifting, see p. 10.2.

Automatic transmission

Connect and tighten the gearbox-oil radiator oil lines to a torque of 25 Nm.

Screw on the four torque converter nuts, turning the engine 1/4 turn each time. To turn the engine, install a head on the central bolt of the crankshaft pulley. Install the flywheel hatch.

Install the thermostat housing and fill with coolant, see p. 3.3.

Connect the two transmission control multi-pin plugs on the automatic transmission.

Attach the selector lever cable and secure the counter support.

Adjust the selector lever cable, see p. 10.4.

Check the oil level, if necessary, top up to the lower edge of the inspection hole, see p. 10.6.

Connect the negative (-) terminal to the battery. Set the clock and set the radio anti-theft code.

The full article is on the online resource [FordBook]