FORD FIESTA 2007 Workshop Manual

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308-03-62 Manual Transmission/'rransaxle 308-03-62
INSTALLATION
Transaxle - 1.25L Duratec-I 6V (Sigma)/Im4L Duratec-1 6V
(Sigma)/l .6L Duratec-1 6V (Sigma)(l 6 1 14 0)
Special Tool(s)
Support Bar, Engine
303-290A (21
-1 40A)
Adapter for 303-290A 303-290-0
1 (2 1 -1 40-0 1 )
Adapter for 303-290A
303-290-02 (21
-1 40-02)
21 14002
I I I
General Equipment
Retaining strap
I Transmission jack I
Materials
Name Specification
Installation
Manual transmission
1 fluid
All vehicles
I. CAUTIONS:
WSD-M2C200-C
&se suitable retaining straps to secure
the transaxle on the transmission jack.
A~ake sure that the two locating dowels
are installed.
Using a suitable transmission jack, install
the transaxle.
2. Install the transaxle right-hand retaining
bolts.
3. Install the transaxle lower retaining bolts.
-- -- -
2006.0 Fiesta 1212006 GI 13293en
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308-03-63 Manual Transmission/Transaxle 308-03-63
INSTALLATION
4. Install the transaxle left-hand retaining bolt. Install the
engine rear mount.
5. Remove the retaining strap. 11. Remove the special tools.
6. Remove the transmission jack.
7. Install the engine and transaxle rear mount
retaining bracket.
12. N0TE:lnstall new exhaust flange nuts and
a new exhaust flange gasket.
Attach the exhaust flexible pipe to the
8. Lower the vehicle. catalytic
converter.
9. Using the special tools, raise the engine and
transaxle assembly.
10. N0TE:Do not tighten the engine rear mount
retaining nuts at this stage.
NOTE:
Install new engine rear mount retaining nuts.
2006.0 Fiesta 1212006 GI1 3293en
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308-03-64 Manual Transmission/Transaxle 308-03-64
INSTALLATION
13. Connect the vehicle speed sensor (VSS) 16. Raise and support the vehicle. For
electrical connector (if equipped). additional information, refer to
Section 100-02 [Jacking and Lifting].
17. CAUTIONS:
Asupport the halfshaft. The inner joint
must not be bent more than 18 degrees.
The outer joint must not be bent more than
45 degrees.
ADO not damage the halfshaft oil seal.
Attach the right-hand halfshaft and the
intermediate shaft to the transaxle.
14' ACAUTION:~~ brake fluid is spilt on the
paintwork, the affected area must be
immediately washed down with cold water.
N0TE:Make sure the spring clip is correctly seated.
Connect the clutch slave cylinder supply
line.
Install the spring clip.
15. Attach the coolant expansion tank to the
bracket. 18.
N0TE:lnstall a
new center bearing cap and
locknuts.
Install the intermediate shaft center bearing
cap.
I. Install the center bearing cap.
2. Attach the heat shield.
3. Install the locknuts.
19. CAUTIONS:
Asupport the halfshaft. The inner joint
must not be bent more than 18 degrees.
The outer joint must not be bent more than
45 degrees.
2006.0 Fiesta 1212006 GI I 3293en
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308-03-65 Manual Transmission/Transaxle 308-03-65
INSTALLATION
ADO not damage the halfshaft oil seal. 21. Install the engine support insulator.
/ / AMake sure the snap ring is correctly
seated.
N0TE:lnstall a new snap ring.
Attach the left-hand halfshaft to the
transaxle.
20m ACAUTION:M~~~ sure that the heat shield
is installed to prevent damage to the ball
joint.
N0TE:The lower arm pinch bolt must be installed ' ' from the rear of the wheel knuckle.
22. Install the accessory drive belt cover.
Attach the lower arm to the wheel knuckle
on both sides.
Vehicles without automated gearshift
23. Attach the gearshift cables to the bracket
and turn the abutment sleeves
counterclockwise.
2006.0 Fiesta 1212006 GI 13293en
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308-03-66 Manual Transmission/'rransaxle 308-03-66
INSTALLATION
24. Attach the gearshift cables to the selector 27. Install the gearshift actuator cover.
levers.
Vehicles with automated gearshift
25. Connect the gearshift actuator electrical
connector (colored grey).
26. Connect the gearshift actuator electrical
connector (colored black).
28. Connect the clutch slave cylinder supply
line.
Install the clip.
All vehicles
29. Connect the reversing lamp switch
electrical connector.
30. Install the starter motor.
2006.0 Fiesta 1212006 GII 3293en
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308-03-67 Manual Transmission/Transaxle 308-03-67
INSTALLATION
Attach the starter motor electrical connector 34. Tighten the engine rear mount outer
/- . to the starter motor. retaining nuts. /'
31. Lower the vehicle. 35. Tighten the engine rear mount center
32. Tighten the strut spring assembly top retaining nut.
mount nuts on both sides.
36. Install the battery tray support bracket.
33. Install the transaxle upper retaining bolts.
Attach the engine wiring harness bracket to
the transaxle.
2006.0 Fiesta 1212006 GI1 3293en
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308103168 Manual Transmission/Transaxle 308103168
INSTALLATION
37. Connect the powertrain control module
(PCM) electrical connector to the PCM.
38. Install the front wheels and tires. For
additional information, refer to
Section
204-04 wheels and Tires].
Vehicles without automated gearshift
39. Adjust the gearshift cables. For additional
information, refer to Section
308-00
[Manual Transmission/Transaxle and Clutch
- General Information].
40. Bleed the clutch system. For additional
information, refer to Section
308m00
[Manual Transmission/Transaxle and Clutch
- General Information].
All vehicles
41. Install the battery tray. For additional
information, refer to Section
41 4-01
[Battery, Mounting and Cables].
42. With the vehicle on a level surface, fill the
transaxle until the oil level is just below the
bottom of the filler hole.
Vehicles with automated gearshift
43m ACAUTION:T~~ worldwide diagnostic
system (WDS) gearshift actuator bleed
option must be carried out
if any part of the
clutch hydraulic system is opened or any
new components are installed.
N0TE:When the WDS gearshift actuator bleed
option is selected, the learn transmission and learn
clutch parameter options will automatically be
completed.
Bleed the clutch system. For additional
information, refer to Section
308-00 [Manual
Transmission/Transaxle and Clutch - General
Information].
2006.0 Fiesta 1212006 GII 3293en
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308=03=69 Manual Transmission/Transaxle 308=03=69
INSTALLATION
Transaxle - 2.OL Duratec-HE (M14)(16 11 4 0)
i
Special Tool(s)
I I Support Bar, Engine
Adapter for 303-290A
303-290-01 (21 -1 40-01
)
General Equipment , I
@ 21 14005
21 14006
I Retaining strap I
Adapter for 303-290A
303-290-05A (2 1
- 1 40-05A)
Adapter for 303-290A
303-290-06 (21 -1 40-06)
I Transmission jack I
Materials
Name Specification
Installation
1. CAUTIONS:
A~se suitable retaining straps to secure
the transaxle on the transmission jack.
A~ake sure that the two locating dowels
are installed.
Using a suitable transmission jack, install
the transaxle.
Manual transmission
1 fluid
2. Install the transaxle right-hand retaining
bolts.
WSD-M2C200-C
2006.0 Fiesta 1212006 G453417en
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308-03-70 Manual Transmission/Transaxle 308-03-70
INSTALLATION
3. Install the transaxle lower retaining bolts. 9. Using the special tools, raise the engine and
transaxle assembly.
f
4. Install the transaxle left-hand retaining bolt.
10. N0TE:Do not tighten the engine rear mount
retaining nuts at this stage.
N0TE:lnstall new engine rear mount retaining nuts.
Install the engine rear mount.
5. Remove the retaining strap.
6. Remove the transmission jack.
7. Lower the vehicle.
8. Install the engine and transaxle rear mount
retaining bracket. 11. Remove the special tools.
12. N0TE:lnstall new exhaust flange nuts and ,
a new exhaust flange gasket.
2006.0 Fiesta 1212006 G453417en
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