Vibrating, Buzzing and Rattling Repair

1. Wedge a block of wood about seven (7) inches long under the clutch pedal. Holding the pedal above its normal position will disengage the clutch cable self adjuster.

2. Open the hood, disconnect the battery negative cable, and raise the vehicle.

3. Remove the nuts attaching the catalytic converter inlet pipe to the turbocharger.

4. Remove the attaching nuts at the catalytic converter outlet-to-muffler inlet flange and the catalytic converter support bracket.

5. Remove the catalytic converter and inlet pipe as an assembly.

6. Remove the driveshaft. If necessary, refer to Section 15-60 of the Merkur XR4Ti Shop Manual.

7. Install a plug in the extension housing seal to prevent fluid leakage.

8. Remove the starter. If necessary, refer to Section 28-02 of the Merkur XR4Ti Shop Manual.

9. Remove the front stabilizer bar to body U-brackets and the body stiffener rod.

10. If equipped, remove the transmission air baffle. A removal and installation procedure is included in the fluid level check procedure at the end of this article.

11. Position a block of wood between the stabilizer bar and the body side rail.

12. Support the transmission with a transmission jack.

13. Remove the bolt attaching the rear mount to the transmission.

14. Remove the bolts attaching the rear mount to the body and remove the mount.

15. Loosen the engine mount attaching nuts until only two (2) or three (3) threads are visible on the end of the stud.
16. Position a block of wood against the engine oil pan and raise the front of the engine. Raise the engine until the stud nuts on the engine mounts contact the crossmember. As the engine tilts downward, lower the transmission jack.

17. Disconnect the wire to the back-up lamp switch.

18. Disconnect the wire to the neutral safety switch.

19. Remove the attaching bolts and raise the transmission shift lever out of the extension housing (TORX No. 40).

20. Remove the snap ring and pull the speedometer cable out of the extension housing.

21. Remove the clutch release lever cover.

22. Pull rearward on the clutch release cable and disengage from the release lever.

23. Remove the attaching screws from the speedometer cable routing clips (two places). Position the cable out of the way on the left side of the vehicle.

24. Remove the bolt attaching the engine rear cover plate to the flywheel housing.

25. Remove the flywheel housing attaching bolts located at the top of the housing.

26. Remove the four (4) remaining flywheel housing attaching bolts.

27. Pull the transmission rearward until the flywheel housing contacts the body. Raise the rear of the transmission and pull rearward to clear the body. Lower the rear of the transmission and pull rearward to remove.

Figure 6:

28. Remove the back-up lamp switch and neutral safety switch from the extension housing, Figure 6.

Figure 7:

29. Using a brass drift and hammer, drive the welsh plug out of the extension housing, Figure 7.

Figure 8:

30. Shift the transmission into reverse gear to gain access to the offset lever roll pin and remove the offset lever roll pin using a 1/8 inch pin punch, Figure 8.

Figure 9:

31. Remove the offset lever and roll pin from the extension housing, Figure 9.

Figure 10:

32. Remove the fifth-gear interlock plate attaching bolts, Figure 10.

Figure 11:

33. Remove the fifth-gear interlock plate, detent spring, and detent plunger, Figure 11.

Figure 12:

34. Remove the extension housing attaching bolts, Figure 12.

Figure 13:

35. Remove the extension housing and gasket. Discard the gasket, Figure 13.

36. Shift the transmission into fourth gear.

37. Position a new extension housing gasket.

Figure 14:

38. Position a new gasket and install the new extension housing (E8RY-7A039-A). Be sure the flat on the countershaft and the matching flat in the extension housing are properly aligned, Figure 14.

NOTE: Be sure that the pin in the extension housing engages the spring on the shift rail properly.

Figure 15:

39. Install the extension housing attaching bolts. Tighten the attaching bolts to 33-36 ft.lbs. (40- 49 N-m), Figure 15. Apply Pipe Sealant (D8AZ- 19540-A), or equivalent, on the threads of the three (3) bolts entering the transmission case.

40. Shift the transmission into reverse gear.

Figure 16:

41. Position the offset lever on the shifter shaft and install the roll pin, using a 1/8 inch pin punch, Figure 16.

Figure 17:

42. Install the welsh plug in the extension housing, Figure 17.

Figure 18:

43. Install the fifth-gear detent plunger and spring, Figure 18.

Figure 19:

44. Install the fifth-gear detent lock plate. Before installing the detent lock plate, apply a nonhardening type sealant on the plate to extension housing mating surface, Figure 19.

Figure 20:

45. Tighten the lock plate attaching bolts to 16-19 ft.lbs. (21 -26 Nm). Coat the detent lock plate attaching bolts with Sealant (EOAZ-19954-A), or equivalent, and install the bolts, Figure 20.
46. Align the transmission input shaft with the clutch pressure plate and push the transmission forward until the flywheel housing contacts the body. Raise the rear of transmission, as necessary, to clear the body. Lower the rear of the transmission and push forward into position. Rock the transmission slightly to align the input shaft and clutch disc splines. Use care to prevent damage to the transmission pilot bearing in the end of the crankshaft.

47. Install the flywheel housing attaching bolts. Tighten the bolts to 28-38 ft.lbs. (38-51 N-m).

48. Install the engine rear cover attaching bolts. Tighten the bolt 28-38 ft.lbs. (38-51 N-m).

49. Remove the stand and block of wood supporting the engine.

50. Raise the transmission jack until the transmission is in its normal position.

51. Tighten the engine mount stud nuts to 50-70 ft.lbs. (68-95 N-m).

52. Lower the transmission.

53. Position the shift lever and install the attaching bolts.

54. Connect the back-up lamp switch wire.

55. Connect the wire to the neutral safety switch.

56. Position the speedometer cable in the extension housing and install the snap ring.

57. Install the attaching screws in the speedometer cable routing clips.
58. Raise the transmission.

59. Position the rear mount and install the body attaching bolts. Tighten the bolts to 25-35 ft. lbs. (34-48 N-m).

60. Install the rear mount to transmission attaching bolt. Tighten the bolt to 50-70 ft.lbs. (68-95 N-m).

61. If equipped, install the transmission air baffle.

62. After removing the block of wood, install the stabilizer bar U-brackets and the body stiffener rod. Tighten the attaching bolts to 33-41 ft.lbs. (45-56 N-m).

63. Connect the clutch cable to the release lever and install the cover.

64. Install the starter.

65. Remove the plug from the extension housing and install the driveshaft.

66. Install the catalytic converter.

67. Install the flange attaching nuts at the converter outlet-to-muffler inlet connection.

68. Install the converter inlet-to-turbocharger attaching nuts.

69. Align the exhaust system and tighten the attaching nuts to 21-30 ft.lbs. (28-40 N-m) at the converter outlet and to 25-35 ft.lbs. (34-48 N-m) at the turbocharger.

70. Lower the vehicle, connect the battery negative cable, and close the hood.

71. Remove the block of wood holding the clutch pedal. Press the clutch pedal to the floor several times to adjust the clutch cable freeplay.