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Section 309 (Manual Transmission-IB5): Installation: Transaxle: Installation

WARNING: This page is about a different car, the 2003 Ford Focus. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Only use new self-locking nuts.
    CAUTION: Make sure that the two locating tubes are installed.
    Fig 1: Installing Transmission Into Position
    G01613386Courtesy of FORD MOTOR CO.
  1. Secure the transmission using a retaining strap and move into installation position using a transmission jack.
  2. Tighten the flange bolts and install the catalytic converter bracket.
    Fig 2: Installing Catalytic Converter Bracket
    G01613387Courtesy of FORD MOTOR CO.
  3. Install the starter motor and tighten the flange bolts.
    1. Starter motor bolt.
    2. Flange bolt.
      Fig 3: Installing Starter Motor
      G01613388Courtesy of FORD MOTOR CO.
  4. Remove the wooden block.
    Fig 4: Removing Wooden Block
    G01613389Courtesy of FORD MOTOR CO.
  5. Lower the vehicle.
  6. Using the special tools, raise the engine and transaxle compartment.
    Fig 5: Raising Engine And Transaxle Compartment Using SST
    G01613390Courtesy of FORD MOTOR CO.
  7. Raise and support the vehicle. For additional information, refer to JACKING & HOISTING .
  8. Install the drive belt cover.
    Fig 6: Installing Drive Belt Cover
    G01613391Courtesy of FORD MOTOR CO.
  9. Install the roll restrictor.
    Fig 7: Installing Roll Restrictor
    G01613392Courtesy of FORD MOTOR CO.
    10. CAUTION: The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
    CAUTION: Use the installation sleeve (supplied with every new oil seal) to protect the oil seal when inserting the front halfshaft.
    NOTE: Make sure the retaining ring is securely in place.
    Fig 8: Installing Left-Hand Front Halfshaft In Transaxle Together With A New Retaining Ring
    G01613393Courtesy of FORD MOTOR CO.
  10. Install the left-hand front halfshaft in the transaxle together with a new retaining ring.
    11. CAUTION: The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
    Fig 9: Inserting Right-Hand Front Halfshaft Into Transaxle
    G01613394Courtesy of FORD MOTOR CO.
  11. Insert the right-hand front halfshaft into the transaxle.
    12. NOTE: Install a new mounting bracket and new nuts.
    Fig 10: Installing Mounting Bracket For Center Bearing On Right-Hand Front Halfshaft
    G01613395Courtesy of FORD MOTOR CO.
  12. Install mounting bracket for center bearing on right-hand front halfshaft.
  13. Install lower suspension arm ball joint on both sides.
    Fig 11: Installing Lower Suspension Arm Ball Joint On Both Sides
    G01613396Courtesy of FORD MOTOR CO.
  14. Install the shift and selector cable.
    • Install the shift and selector cable end fittings to the shift and selector lever.
    • Install the shift and selector cable to the bracket by turning the lower part of abutment clockwise and the upper part counter clockwise.
      Fig 12: Installing Shift And Selector Cable
      G01613397Courtesy of FORD MOTOR CO.
  15. Top up the transaxle with manual transmission fluid until fluid level is 5 to 10 mm below the lower edge of the check hole.
    Fig 13: Identifying Transaxle Filler Plug
    G01613398Courtesy of FORD MOTOR CO.
  16. Close the cover on the shift and selector cable.
    Fig 14: Closing Cover On Shift And Selector Cable
    G01613399Courtesy of FORD MOTOR CO.
  17. Install the catalytic converter assembly. For additional information, refer to EXHAUST SYSTEM .
  18. Tighten the upper flange bolts and starter motor bolts.
    1. Flange bolts.
    2. Starter motor bolts and ground lead.
      Fig 15: Tightening Upper Flange Bolts And Starter Motor Bolts
      G01613400Courtesy of FORD MOTOR CO.
  19. Install the rear engine mounting bracket.
    Fig 16: Installing Rear Engine Mounting Bracket
    G01613401Courtesy of FORD MOTOR CO.
  20. Using the special tool, raise the engine and transaxle until it becomes possible to install the rear engine mounting.
    Fig 17: Raising Engine And Transaxle Using SST
    G01613402Courtesy of FORD MOTOR CO.
  21. Install the rear engine mounting.
    Fig 18: Installing Rear Engine Mounting
    G01613403Courtesy of FORD MOTOR CO.
  22. Install the shift cable bracket mounting retainer.
    Fig 19: Installing Shift Cable Bracket Mounting Retainer
    G01613404Courtesy of FORD MOTOR CO.
  23. Remove the special tools.
    Fig 20: Removing Special Tools
    G01613405Courtesy of FORD MOTOR CO.
  24. Connect the reversing light switch connector.
    Fig 21: Connecting Reversing Light Switch Connector
    G01613406Courtesy of FORD MOTOR CO.
  25. Connect the vehicle speed sensor (VSS) connector.
    Fig 22: Connecting Vehicle Speed Sensor (VSS) Connector
    G01613407Courtesy of FORD MOTOR CO.
  26. Connect the vacuum hoses.
    Fig 23: Connecting Vacuum Hoses
    G01613408Courtesy of FORD MOTOR CO.
  27. Connect the brake servo vacuum hose.
    Fig 24: Connecting Brake Servo Vacuum Hose
    G01613409Courtesy of FORD MOTOR CO.
    28. WARNING: Escaping brake fluid. Do not allow brake fluid to come into contact with the skin or the eyes. If brake fluid does come into contact with the skin or the eyes, rinse the affected areas with water immediately. Failure to follow these instructions may result in personal injury.
    CAUTION: If brake fluid is spilled on the paintwork, the affected area must be immediately washed down with cold water.
  28. Install the clutch slave cylinder high-pressure line.
    • Insert the clutch slave cylinder high-pressure line in the bracket.
      Fig 25: Installing Clutch Slave Cylinder High-Pressure Line
      G01613410Courtesy of FORD MOTOR CO.
  29. Bleed the clutch hydraulic system. For additional information, to MANUAL TRANSMISSION, CLUTCH & TRANSFER CASE - GENERAL INFORMATION .
  30. Install the intake pipe.
    Fig 26: Installing Intake Pipe
    G01613411Courtesy of FORD MOTOR CO.
  31. Install the air cleaner.
    1. Connect the plug of the MAF sensor.
    2. Connect the intake pipe.
      Fig 27: Installing Air Cleaner
      G01613412Courtesy of FORD MOTOR CO.
  32. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  33. Tighten the strut and spring assembly top mount nuts on both sides.
    Fig 28: Tightening Strut And Spring Assembly Top Mount Nuts On Both Sides
    G01613413Courtesy of FORD MOTOR CO.
  34. Adjust the gearshift mechanism. For additional information, to MANUAL TRANSMISSION, CLUTCH & TRANSFER CASE - GENERAL INFORMATION .
    35. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.
  35. Finishing operations:
    • Carry out a road test to enable the powertrain control module (PCM) to collect data.
    • Check the routing of the vacuum hoses and wiring and secure them with cable ties.
    • Check fluid levels after the road test and correct as necessary.
    • Check the engine and cooling system for leaks (visual inspection).
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