lock FORD FIESTA 2007 Workshop Manual

308-03-58 Manual Transmission/Transaxle 308-03-58
ASSEMBLY
29. N0TE:The transaxle housing must not Correct installation position for the selector
contact the press table. Support the input shaft interlock mechanism.
shaft splines.
Using the special tool and a suitable press,
install the fifth gear.
33. Install the selector shaft interlock
mechanism.
Apply sealant to the thread.
30. Mount the transaxle on the mounting stand.
31. N0TE:lnstall a new fifth gear snap ring.
Install the fifth gear snap ring.
1. Install the snap ring onto the special tool.
2. Install the special tool and push on the snap
ring.
34. N0TE:Align the gear synchronizer to the
marks.
Assemble the fifth gear synchronizer.
I. Fifth gear.
2. Synchronizer ring.
3. Synchronizer assembly.
32. Make sure that the selector shaft is in the 4. Retaining plate.
neutral position.
2006.0 Fiesta 1212006 G23119en
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308-03-59 Manual Transmission/Transaxle 308-03-59
ASSEMBLY
35. N0TE:lnstall a new fifth gear synchronizer
assembly snap ring.
1 , N0TE:Use a new selector fork retaining pin.
lnstall the fifth gear synchronizer assembly
and the selector fork.
lnstall the retaining pin.
lnstall the snap ring.
36. Apply sealer evenly to the inside edge of
the fifth gear housing mating face.
37. lnstall the fifth gear housing cover.
38. lnstall the selector lever.
lnstall the bellows.
39. Engage the fifth gear.
Turn the selector shaft clockwise as far as
possible and push the shaft in.
40. N0TE:lnstall new halfshaft oil seals.
Using the special tools, install both halfshaft
oil seals (left-hand side shown).
2006.0 Fiesta 1212006 G23119en
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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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308-03-72 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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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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Manual Transmission/Transaxle External
308-06-8 Controls 308-06-8
REMOVAL AND INSTALLATION
Gearshift Cables(l6 575 0)
Removal 6. Remove the gearshift cables cover.
I. Remove the gearshift lever.
For additional information, refer to Gearshift
Lever in this section.
2. Remove the air cleaner. For additional
information, refer to Section
303-12 [Intake
Air Distribution and Filtering].
3. Raise and support the vehicle. For additional
information, refer to Section
100-02 [Jacking
and Lifting].
4. Remove the exhaust front hanger insulator.
5. Detach the exhaust heat shield from the floor
panel.
Slide the heat shield backwards.
7. Detach the gearshift cables from the
transaxle.
I. Detach the gearshift cable and the selector
cable from the selector levers.
2. Turn the abutment sleeves clockwise and
detach the cables from the bracket.
8. Detach the gearshift cables from the
retaining clip.
2006.0 Fiesta 1212006 GI 86745en
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Manual Transmission/Transaxle External
308-06-1 0 Controls 308-06-1 0
REMOVAL AND INSTALLATION
3. Raise and support the vehicle. For additional 7. Install the exhaust front hanger insulator.
information, refer to Section
100-02 [Jacking
and Lifting].
4. Attach the gearshift cables to the bracket
and turn the abutment sleeves
counterclockwise.
6. Attach the exhaust heat shield to the floor
panel.
Slide the heat shield forwards. 8.
Attach
the gearshift cables to the retaining
clip.
9. Attach the selector cable to the retaining clip.
10. Install the gearshift lever.
For additional information, refer to
Gearshift Lever in this section.
11. Install the air cleaner. For additional
information, refer to Section
303-12 [Intake (
Air Distribution and Filtering].
2006.0 Fiesta 1212006 GI 86745en
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309-00-2 Exhaust System 309-00-2
SPECIFICATIONS
Lubricants. Fluids. Sealers and Adhesives I Specificat I
Specificat
I ion I
I ion I/- ,
Anti-seize grease I SA-MI C91 I 'c-
Lubricant
Torque Specifications
I Description I Nm I Ibf I Ib-in I
Catalytic converter to exhaust flexible pipe retaining
nuts
- All except vehicles with diesel engine
Catalytic converter to turbocharger retaining nuts
-
Vehicles with I .4L diesel engine
Catalytic converter to turbocharger retaining clamp
- Vehicles with 1.6L diesel engine
Catalytic converter to muffler and tailpipe assembly
clamp retaining nut
- Vehicles with 2.OL engine
Exhaust flexible pipe to catalytic converter clamp
retaining nut
- Vehicles with diesel engine
Exhaust flexible pipe to exhaust manifold retaining
1 nuts
Turbocharger heat shield upper retaining screws
-
Vehicles with I .4L diesel engine
Turbocharger heat shield lower retaining bolts
-
Vehicles with I .4L diesel engine
Catalytic converter heat shield retaining screws
-
Vehicles with I .6L diesel engine
Exhaust flexible pipe to muffler and tailpipe
assembly retaining nuts
- Vehicles with diesel
engine
Catalytic converter support bracket to engine block
retaining nuts
- Vehicles with 1.4L or 1.6L engine
Catalytic converter support bracket to engine block
retaining nuts
- Vehicles with 1.3L or 1.4L diesel
engine
Catalytic converter support bracket to engine block retaining bolts
- Vehicles with I .6L diesel engine
I Catalytic converter to support bracket retaining nuts I 25 I 18 I - 1
Catalytic converter to catalytic converter support
bracket retaining bolts
- Vehicles with 1.6L diesel
engine
Catalytic converter to muffler and tailpipe assembly
retaining nuts
- Vehicles with 1.6L diesel engine
I Heated oxygen sensor (H02S) I 47 I 35 I - I
I Catalytic monitor sensor I 47 I 35 I - I
2006.0 Fiesta 1212006 G149908en
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31 0-00-5 Fuel System - General Information 31 0-00-5
GENERAL PROCEDURES
Quick Release Coupling
i 1 General Equipment 2. Disconnect the fuel line quick release
coupling.
Flat-bladed screwdriver
Disconnection
WARNINGS:
A Do not carry lighted tobacco or open flame
of any type when working on or near any
fuel related components. Highly flammable
vapors are always present and can ignite.
Failure to follow these instructions may
result in personal injury.
A This procedure involves fuel handling. Be
prepared for fuel spillage at all times and
always observe fuel handling precautions.
Failure to follow these instructions may
result in personal injury. 3.
Disconnect the fuel line quick release
coupling.
1. Pull the fuel line quick release coupling
CAUTI0N:Fuel injection equipment is locking tang.
manufactured to very precise tolerances 2. Push the clip through the fuel line quick
and fine clearances. It is therefore essential release coupling to release the fuel line.
that absolute cleanliness is observed when I
i
working with these components. Always
install blanking plugs to any open orifices
or lines.
N0TE:Fuel supply line connectors are white or are
identified by a white band. Fuel return line
connectors are red or are identified by a red band.
1. Release the fuel system pressure.
For additional information, refer to: Fuel
System Pressure Release (31
0-00 Fuel
Svstem - General Information, General
2. Disconnect the fuel line quick release 4. Disconnect the fuel line quick release
coupling. coupling.
1. Press the fuel line quick release coupling 1. Press the fuel line quick release coupling
locking tangs. locking tangs.
2006.0 Fiesta 1212006 GI 81 92en
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