engine FORD FIESTA 2007 Workshop Manual

Automatic Transmission/Transaxle -
Vehicles With: 4-Speed Automatic
Transmission (AW81-40)
REMOVAL AND INSTALLATION
4. Loosen the strut and spring assembly top 7. Detach the ground cable from the transaxle.
mount nuts by three turns on both sides.

8. Disconnect the turbine shaft speed (TSS)
5. Detach the engine ground cable from the sensor
electrical connector.
transaxle.
9. Disconnect the transaxle breather hose.
6. Remove the transaxle upper retaining bolts.
Detach the engine wiring harness bracket
from the transaxle.
2006.0 Fiesta 1212006 G371506en
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Automatic Transmission/Transaxle -
Vehicles With: 4-Speed Automatic
Transmission (AW81-40)
REMOVAL AND INSTALLATION
17. Disconnect the ignition switch to starter Support
the exhaust flexible pipe with a
motor solenoid and battery to starter motor suitable
support wrap or suitable splint.
solenoid cables.
21. Detach the exhaust flexible pipe from the
18. Remove the accessory drive belt cover. catalytic
converter.
Discard the nuts and the gasket.
19. Remove the engine support insulator.
22m &AUTION:L~~~~ the tie-rod end retaining
nut in place to protect the ball joint stud.
N0TE:Use a 5mm Allen key to prevent the ball
joint stud from rotating.
20m ACAUTION:~~~~ bending of the exhaust
flexible pipe may cause damage resulting
in failure. Loosen
the right-hand tie-rod end retaining
nut.
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Automatic Transmission/Transaxle -
Vehicles With: 4-Speed Automatic
307-01 -67 Transmission (AW81-40) 307-01 -67
REMOVAL AND INSTALLATION
See - Transmission Fluids.
27. Lower the vehicle.
28. Remove the battery tray support bracket.
Allow the fluid to drain into a suitable
container.
For additional information, refer to: Health
and Safety Precautions
(1 00-00 General
Information, Description and Operation).
See
- Transmission Fluids.
30.
Install the special tools.
29m AWARNING:~~~~ releasing the
transmission fluid, take care to prevent
scolding. Failure to follow this instruction
may result in personal injury.
31. Remove the engine and transaxle rear
A CAUTI0N:Plug the transmission fluid
mount.
cooler feed and return lines to prevent fluid
loss or dirt ingress.
Discard the nuts.
For additional information, refer to: Health
and Safety Precautions
(1 00-00 General
Information, Description and Operation).
See
- Transmission Fluids.
N0TE:Mark the position of the feed and return
lines to aid installation.
Detach the transmission fluid cooler lines
from the transmission.
1. Push the transmission fluid cooler line quick
release connector onto the transmission.
2. Press together the retaining tabs and detach
the transmission fluid cooler line from the
transmission.
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Automatic Transmission/Transaxle -
Vehicles With: CSpeed Automatic
Transmission
(AW81-40)
REMOVAL AND INSTALLATION
32. Using the special tools, lower the engine Rotate the torque converter to gain access
and transaxle assembly. to the nuts.
Discard the nuts.
33. Remove the engine and transaxle rear
mount retaining bracket.
37. Remove the transaxle lower retaining bolts.
34. Raise and support the vehicle. 38. N0TE:Secure the transaxle with a securing
strap to the transmission jack.
For additional information, refer to: Lifting
(1 00-02 Jacking and Lifting, Description Using
a suitable transmission jack, support
and Operation). the transaxle.
35. Remove the starter motor.
36. Remove the torque converter retaining
nuts.
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Automatic Transmission/Transaxle -
Vehicles With: 4-Speed Automatic
REMOVAL AND INSTALLATION
39. Tilt the engine and transaxle assembly Check
the installation depth of the torque
forwards and insert a suitable wooden converter.
/ block. 1. Lay
a straight edge on the transaxle flange.
2. Check the installation depth between the
transaxle flange and the torque converter
centering spigot.
40. Remove the transaxle right-hand retaining
bolts.
41m ~CAUTION:M~~~ sure the torque
converter remains in the transaxle.
3m ~CAUTION:T~~ torque converter must
Using the transmission jack and remove the remain
at the correct installation depth
transaxle. during the entire installation.
N0TE:Secure the transmission with the securing
Installation strap.
N0TE:Make sure that the two locating dowels are
ACAUTION:T~~ torque converter must installed.
remain at the correct installation depth
during the entire installation.
N0TE:Before installing the bolts in the
transmission, the torque converter studs must be
aligned with the holes in the drive plate.
Install the torque converter.
Lubricate the torque converter centering
spigot with grease.
*' ACAUTION:T~~ torque converter hub must
engage fully with the oil pump drive gear.
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Automatic Transmission/Transaxle -
Vehicles With: 4-Speed Automatic
Transmission
(AW81-40)
REMOVAL AND INSTALLATION
Using a suitable transmission jack, install
the transaxle. 1. Rotate the torque converter to gain access
to the nut bolts.
/I
4. Install the transaxle right-hand retaining 10. Install the starter motor.
bolts.
11. Lower the vehicle.
5. Remove the wooden block. 12. Install the engine and transaxle rear mount
6. Remove the securing strap. retaining
bracket.
7. Remove the transmission jack.
8. lnstall the transaxle lower retaining bolts.
9. N0TE:lnstall new torque converter retaining
nuts.
lnstall the torque converter retaining nuts.
2006.0 Fiesta 1212006 G371506en
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Automatic Transmission/Transaxle -
Vehicles With: 4-Speed Automatic
307-01 -71 Transmission (AW81-40) 307-01 -71
REMOVAL AND INSTALLATION
13. Using the special tools, raise the engine 16. Attach the transmission fluid cooler feed
and transaxle assembly. and
return lines to the automatic
I I transmission.
14. N0TE:Do not tighten the engine rear mount
retaining nuts at this stage.
17. Raise and support the vehicle.
N0TE:lnstall new engine rear mount retaining nuts. For
additional information, refer to: Lifting - -
Install the engine rear mount retaining nuts.
15. Remove the special tools.
(1 00-02 Jacking and Lifting, Description
and Operation).
18. CAUTIONS:
A~he 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 seal.
Attach the right-hand halfshaft and the
intermediate shaft to the transaxle.
Remove the protective sleeve before fully
installing the halfshaft.
19. N0TE:lnstall a new center bearing cap and
locknuts.
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Automatic Transmission/Transaxle -
Vehicles With: 4-Speed Automatic
Transmission (AW81-40)
REMOVAL AND INSTALLATION
24. Remove the exhaust flexible pipe support. Install
the transmission fluid level indicator
, 25. Install the engine support insulator. tube
to the transaxle.
26. Install the accessory drive belt cover. 29.
Attach the selector lever cable retaining
bracket to the transaxle.
27. Connect the ignition switch to starter motor
30, Attach the selector lever cable to the solenoid and battery to starter motor
solenoid cables. manual
shift lever.
31. Adjust the selector lever cable.
28m ACAUTION:M~~~ sure the transmission
fluid level indicator tube is fully located in For
additional information, refer to: Selector
the transmission housing. Lever Cable
Adjustment (307-05 f Automatic Transmission/Transaxle
External Controls - Vehicles With:
4Speed Automatic Transmission
(AW81-40), General Procedures).
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Automatic Transmission/Transaxle -
Vehicles With: 4-Speed Automatic
Transmission (AW81-40)
REMOVAL AND INSTALLATION
39. Install the engine wiring harness support 42. Tighten the engine rear mount center
brackets. retaining nut.
40. Attach the engine ground cable to the 43. Install the battery tray support bracket.
transaxle.
44. Tighten the strut and spring assembly top
41. Tighten the engine rear mount outer mount
retaining nuts on both sides.
retaining nuts.
45. Install the front wheels and tires.
For additional information, refer to: Wheel
and Tire
(204-04 Wheels and Tires,
Removal and Installation).
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Automatic Transmission/Transaxle -
Vehicles With: 4-Speed Automatic
307-01 -76 Transmission
(AW81-40) 307-01 -76
REMOVAL AND INSTALLATION
46. Install the battery tray.
For
additional information, refer to: Battery
Tray (414-01 Battery, Mounting and
Cables, Removal and Installation).
47. Connect the powertrain control module
(PCM) electrical connector to the PCM.
For
additional information, refer to:
Powertrain
Control Module (PCM) - 1.25L
Duratec-1 6V (Sigma)ll.4L Duratec-1 6V
(Sigma)ll .6L Duratec-1 6V (Sigma) (303-1 4
Electronic Engine Controls, Removal and
Installation).
48. Install the air cleaner.
For additional information, refer to: Air
Cleaner - 1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)ll.GL Duratec-1 6V
(Sigma) (303-1 2 Intake Air Distribution
and
Filtering, Removal and Installation).
49. Check the transmission fluid level and top
up with
clean automatic transmission fluid
if necessary.
For
additional information, refer to:
Transmission
Fluid Level Check (307-01
Automatic
Transmission/Transaxle -
Vehicles With: 4-Speed Automatic
Transmission
(AW81-40), General
Procedures).
50.
N0TE:Only carry out the following step
when a new
transaxle has been installed.
Using worldwide diagnostic system (WDS),
reset the transmission control module (TCM).
2006.0 Fiesta 1212006 G371506en
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