FORD FIESTA 2007 Workshop Manual

Automatic Transmission/Transaxle External
Controls -Vehicles With: 4-Speed Automatic
Transmission
(AW81-40)
REMOVAL AND INSTALLATION
Selector Lever Cable
', General Equipment Slide the heat shield backwards.
1 Draw cord
Removal
1. Detach the selector cable from the retaining
clip.
2. Raise and support the vehicle.
For additional information, refer to: Lifting ( (100-02 Jacking and Lifting, Description
and Operation).
3. Remove the exhaust front hanger insulator.
4. Detach the exhaust heat shield from the floor
panel.
5. Unclip the selector lever cable from the
right-hand side of the bracket.
6. Detach the selector lever cable from the
manual shift lever.
I. Detach the selector lever cable from the
manual shift lever.
2. Detach the selector lever cable from the
selector lever cable bracket.
2006.0 Fiesta 121zoo6 G388013en
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- -
Automatic Transmission/Transaxle External
Controls -Vehicles With:
4Speed Automatic
307-05-8 Transmission
(AW81-40) 307-05-8
REMOVAL AND INSTALLATION
7. Attach a suitable length of draw cord to the 2. Using the draw cord, pull the selector lever
transaxle end of the selector lever cable and
cable through the floor panel.
secure
it to the transaxle. 3. Install the selector lever cable grommet.
8. Lower the vehicle.
9. Remove the floor console.
For additional information, refer to: Floor
Console
(501 -1 2 Instrument Panel and
Console, Removal and lnstallation).
10. Detach the selector lever cable from the
transmission selector lever.
1. Shift the selector lever to the "P" (PARK)
position.
2. Detach the selector lever cable.
3. Pull the selector lever cable locking pin and
detach the selector lever cable outer sleeve.
4. Attach the selector lever cable to the selector
lever.
11. Remove the selector lever cable grommet.
12. Remove the selector lever cable.
1. Shift the selector lever to the "P" (PARK)
position.
2. Attach the selector lever cable outer sleeve.
3. Attach the selector lever cable.
5. Install the floor console.
For additional information, refer to: Floor
Console
(501-12 lnstrument Panel and
Console, Removal and lnstallation).
6. Raise and support the vehicle.
For additional information, refer to: Lifting
(100-02 Jacking and Lifting, Description
and Operation).
Pull the cable and draw cord through the floor 7. Remove the draw cord.
panel. 8. Attach the selector lever cable to the manual
Installation
shift lever. f
1. Attach the selector lever cable to the selector''-
1. Attach the draw cord to the transaxle end of lever cable bracket.
the selector lever cable.
2006.0 Fiesta 1212006 G388013en
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Automatic Transmission~~ransaxle External
Controls -Vehicles With: 4-Speed Automatic
307-05-9 Transmission
(AW81-40) 307-05-9
REMOVAL AND INSTALLATION
2. Attach the selector lever cable to the manual 11. Install the exhaust front hanger insulator.
shift lever.
12. Lower the vehicle. 9. Clip the selector lever cable into the
right-hand side of the bracket. 13.
Attach the selector cable to the retaining
clip.
10. Attach the exhaust heat shield to the floor
panel. 14.
Adjust the selector lever cable.
Slide the heat shield forwards. For additional information, refer to: Selector
Lever Cable Adjustment
(307-05
Automatic Transmission/Transaxle
External Controls - Vehicles With:
4-Speed Automatic Transmission
(AW81-40), General Procedures).
2006.0 Fiesta 1212006 G388013en
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Automatic Transmission/Transaxle External
Controls -Vehicles With:
4Speed Automatic
Transmission
(AW81-40)
REMOVAL AND INSTALLATION
Selector Lever
Removal
1. Remove the floor console. 4. Remove the transmission selector lever.
2. Detach the selector lever cable from the
transmission selector lever.
1. Shift the selector lever to the "P" (PARK)
position.
2. Detach the selector lever cable.
3. Pull the selector lever cable locking pin and
detach the selector lever cable outer sleeve.
3.
Disconnect the transmission selector lever
electrical connector.
Installation
1. Install the transmission selector lever.
2. Connect the transmission selector lever
electrical connector.
3. Attach the selector lever cable to the
transmission selector lever.
2006.0 Fiesta 1212006 G294549en
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Automatic Transmission/Transaxle External
Controls -Vehicles With:
4Speed Automatic
307-05-1
1 Transmission (AW81-40) 307-05-1 1
REMOVAL AND INSTALLATION
1. Shift the selector lever to the "P" (PARK)
position.
2. Attach the selector lever cable outer sleeve.
3. Attach the selector lever cable.
4. Install the floor console.
5. Adjust the selector lever cable.
For additional information, refer to Selector
Lever Cable Adjustment
- in this section.
2006.0 Fiesta 1212006 G294549en
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Automatic Transmission/Transaxle External
Controls
- Vehicles With: 4-Speed Automatic
307-05-1
2 Transmission (AW81-40) 307-05-1 2
REMOVAL AND INSTALLATION
Selector Lever Bezel
Removal
1. Remove the transmission selector lever
knob.
For additional information, refer to
Transmission Selector Lever Knob
- in this
section.
2. Remove the selector lever bezel (selector
lever assembly shown removed for clarity).
Unclip the bezel.
Unclip the lamp.
Installation
1. Install the selector lever bezel (selector lever
assembly shown removed for clarity).
Clip the bezel.
Clip the lamp.
ELEOOl
2. Install the transmission selector lever knob.
For additional information, refer to
Transmission Selector Lever Knob
- in this
section.
2006.0 Fiesta 1212006 G294550en
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Automatic TransmissionlTransaxle External
Controls -Vehicles With: 4-Speed Automatic
307-05-1
3 Transmission (AW81-40) 307-05-1 3
REMOVAL AND INSTALLATION
Selector Lever Knob
, > .
Removal
1. Remove the floor console.
2. Disconnect the overdrive (OID) switch
electrical connector (selector lever assembly
shown removed for clarity).
3. Remove the selector lever knob.
Remove the bolt. i
Installation
1. Install the selector lever knob.
Position the knob.
lnstall the bolt.
2. Connect the OID switch electrical connector
(selector lever assembly shown removed for
clarity).
3. Install the floor console.
2006.0 Fiesta 1212006 G294551 en
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Automatic Transmission/Transaxle External
Controls -Vehicles With: 4-Speed Automatic
307-05-1 4 Transmission (AW81-40) 307-05-1 4
DISASSEMBLY AND ASSEMBLY
Selector Lever
Materials Unclip the lamp.
I I Name S~ecification
1 Grease I S-MlC1021-A I
Disassembly
N0TE:Use vice jaw protectors for all work to be
done in the vice.
1. Disconnect the overdrive (OID) switch
electrical connector.
Assembly
1. To assemble, reverse the disassembly
procedure.
Coat all sliding and turning parts with grease.
2. Remove the selector lever knob.
Remove the bolt.
3. Disassemble the selector lever.
Remove the brake shift interlock actuator.
Remove the selector lever bezel.
Unclip the bezel.
2006.0 Fiesta 1212006 G388014en
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Manual TransmissionlTransaxle and Clutch -
General lnformation
SECTION 308-00 Manual Transmission/Transaxle and
Clutch
- General lnformation
VEHICLE APPLICATION:2006.0 Fiesta
CONTENTS PAGE
SPECIFICATIONS
Specifications.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308-00-2
Clutch Dimensions
........................................................................\
.................................. 308-00-2
DIAGNOSIS AND TESTING
Manual Transaxle and Clutch ........................................................................\
..................... 308-00-3
Inspection and Verification
................................................................... ......................... 308-00-3
Gear shifting concerns
........................................................................\
........................... 308-00-3
Transaxle noise concerns
........................................................................\
........................... 308-00-3
Oil leakage concerns
........................................................................\
.................................. 308-00-3
GENERAL PROCEDURES
Gearshift Cable Adjustment.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (1 6 51 3 0) 308-00-1 1
( I Clutch System Bleeding ........................................................................\
......... (16 843 0) 308-00-12
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Manual Transmission/Transaxle and Clutch -
General Information
SPECIFICATIONS
Lubricants, Fluids, Sealers and Adhesives
Description Specificat
I ions I
Manual transmission fluid
I High melting point grease
Super DOT 4 brake fluid
Clutch Dimensions
I Description I Litres 1 '"<
fluid: 10 - 15
mm below the lower edge of the fluid
filler plug
--
2.3
Description
Pedal travel
Worn clutch disc discard thickness*
Clutch disc diameter:
1.25Ll1.4L Duratec-1 6V (Sigma)
Clutch disc diameter:
1.6L Duratec-I 6V (Sigma)
Clutch disc diameter:
2.OL Duratec-HE (M14)
Clutch disc diameter: 1.4U1.6L Duratorq-TDCi (DV) Diesel
Clutch disc diameter:
1.3L Duratec-8V (Rocam)
mm
135k5
7
190
210
220
210 190
* When the discard thickness has been reached, install a new clutch disc.
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