manual transmission FORD FIESTA 2007 Workshop Manual

308-03-72 Manual Transmission/Transaxle 308-03-72
INSTALLATION
20. Attach the gearshift cables to the bracket 23. Connect the reversing lamp switch
and turn the abutment sleeves electrical connector.
counterclockwise.
I I
24. Install the starter motor.
21. Attach the gearshift cables to the selector
levers.
22. Install the gearshift cables cover. 25.
Install the wiring harness retaining bracket. Attach the wiring harness to the retaining
bracket.
26. Lower the vehicle.
2006.0 Fiesta 1212006 G453417en
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308-03-73 Manual Transmission/Transaxle 308-03-73
INSTALLATION
27. Attach the power steering high-pressure 30. Tighten the engine rear mount outer
/ line retaining bracket to the transaxle. retaining nuts. I
28. Install the transaxle upper retaining bolts. 31. Tighten the engine rear mount center
retaining nut.
29. Install the engine wiring harness bracket.
32. Install the battery tray support bracket.
33. Install the front wheels and tires.
For additional information, refer to: Wheel
and Tire
(204-04 Wheels and Tires,
Removal and Installation).
- -- -- --
2006.0 Fiesta 1212006 G453417en
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308-03-74 Manual Transmission/Transaxle 308-03-74
INSTALLATION
34. Adjust the gearshift cables.
For additional information, refer to:
Gearshift Cable Adjustment
(308-00
Manual Transmission/Transaxle and
Clutch
- General Information, General
Procedures).
35. Bleed the clutch system.
For additional information, refer to: Clutch
System Bleeding (308-00 Manual
Transmission/Transaxle and Clutch -
General Information, General Procedures).
36, Install the battery tray.
For additional information, refer to: Battery
Tray
- 2.OL Duratec-HE (M14) (414-01
Battery, Mounting and Cables, Removal
and
Installation).
37. With the vehicle on a level surface, fill the
transaxle until the fluid level is just below
the bottom of the filler hole.
2006.0 Fiesta 1212006 G453417en
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Manual Transmission/Transaxle External
Controls
if
SECTION 308-06 Manual Transmission/Transaxle
External Controls
VEHICLE APPLICATION:2006.0 Fiesta
CONTENTS PAGE
SPECIFICATIONS
Specifications
........................................................................\
.............................................. 308-06-2
DESCRIPTION AND OPERATION
External Controls
........................................................................\
........................................ 308-06-3
DIAGNOSIS AND TESTING
External Controls
........................................................................\
........................................ 308-06-5
Inspection and Verification
........................................................................\
.......................... 308-06-5
Symptom Chart
........................................................................\
........................................... 308-06-5
........................................................................\
........................................... Pinpoint Tests.. 308-06-5
REMOVAL AND INSTALLATION
Gearshift Lever
........................................................................\
................. (1 6 524 0)
Gearshift Cables
........................................................................\
.................... (16 575 0)
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Manual Transmission/Transaxle External
Controls
SPECIFICATIONS
Torque Specifications
I Gearshift mechanism to floor assembly I 9 I I 80 I
Description
Shift and selector cable bushing.
2006.0 Fiesta 1212006 GI 8149en
Nm
9
Exhaust flange bolts
Gearshift lever
I b-ft
47
5
Ib-in 80
35
44
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Manual Transmission/Transaxle External
Controls
DESCRIPTION AND OPERATION
External Controls
2006.0 Fiesta 1212006 GI 63328en
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Manual Transmission/Transaxle External
308-0614 Controls 308-06-4
DESCRIPTION AND OPERATION
Item Description
1 2 1 Selector cable I
1 3 1 Body duct I
The selector cable is moved in an axial direction
when a gear is selected with the gear lever. In the
internal gearshift mechanism, this axial movement
translates into the selection of the shift slot.
The shift cable is also moved in an axial direction
when a gear is selected with the gear lever. In the
internal gearshift mechanism, this axial movement
is used to engage the corresponding gear.
The selector cable is marked black and the shift
cable is marked white.
2006.0 Fiesta 1212006 GI 63328en
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Manual Transmission/Transaxle External
308-06-5 Controls
308-06-5
External Controls
Inspection and Verification 4. If an obvious cause for an observed or reported
concern is found, correct the cause (if possible)
1. Verify the customer concern. before proceeding to the next
step.
2. Visually inspect for obvious signs of mechanical 5.
If the concern is not visually evident, verify the
damage. symptom
and refer to the Symptom Chart.
3. Make sure that the gearshift cables are correctly
routed and not under any tension from other
components.
Symptom Chart
Symptom
External controls do not
operate freely. Possible Sources
Action
Gearshift cables incorrectly
adjusted.
Gearshift lever damaged.
Selector mechanism damaged.
Gearshift cables damaged. ADJUST
the gearshift cables.
REFER to: Gearshift Cable
Adjustment
- Vehicles With:
5-Speed Manual Transaxle
(iB5) (308-00 Manual Trans-
mission/Transaxle and Clutch
- General Information,
General Procedures).
GO to Pinpoint Test A.
Pinpoint Tests
PINPOINT TEST A : STIFF GEARSHIFT
TEST CONDITIONS
DETAILSIRESU LTSIACTIONS
Al: CHECK THE GEARSHIFT LEVER
Detach the gearshift cables from the gearshift
lever.
Is the gearshift lever difficult to operate?
+ Yes
Install a new gearshift lever.
REFER to: Gearshift Lever (308-06 Manual
TransmissionlTransaxle External Controls,
Removal and Installation).
-, No
GO to
A2.
A2: CHECK THE GEARSHIFT CABLES
Attach the gearshift cables to the gearshift lever.
2006.0 Fiesta IZIZOO~ G37664en
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Manual Transmission/Transaxle External
Controls
DIAGNOSIS AND TESTING
TEST CONDITIONS DETAILSIRESULTSIACTIONS
~etach the gearshift cables from the transaxle.
Is the gearshift lever difficult to operate?
+ Yes
Install new gearshift cables.
REFER to: Gearshift Cables (308-06 Manual
Transmission/Transaxle External Controls,
Removal and Installation).
+ No
Install a new selector mechanism.
REFER to: Transaxle (308-03 Manual
Trans-
mission/Transaxle, Disassembly).
2006.0 Fiesta 1212006 G37664en
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Manual Transmission/Transaxle External
Controls
REMOVAL AND INSTALLATION
Gearshift Lever(l6 524 0)
Removal
I. Remove the gearshift lever trim panel.
Disconnect the cigar lighter electrical
connector.
2. Detach the gearshift cables from the
gearshift lever.
4. Remove the gearshift lever front retaining
bolts.
5. Remove the gearshift lever.
Remove the bolts.
Installation
1. To install, reverse the removal procedure. 3. Detach the gearshift cables from the
retaining bracket. 2. Adjust the gearshift cables. For additional
information, refer to Section
308-00 [Manual Turn the abutment sleeves clockwise. Transmission/Transaxle and Clutch - General
Information].
2006.0 Fiesta 1212006 GI 86744en
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