Installation
Installation
1. Install transmission to engine
- Remove counterhold 999 5656.
- Use mobile jack and transmission fixture to adjust the height and angle.
Align transmission to engine.
Reinstall screws (7 x).
- First tighten diagonally to light contact.
- Then final tighten alternately to 50 Nm (36.9 ft.lb).
NOTE: Check carefully when tightening screws that the guide bushings locate correctly in their guide holes and that the torque converter cover is in contact with the engine before tightening.
- Remove fixture and mobile jack from transmission.
2. Install torque converter screws
NOTE: Use new screws.
- Align torque converter to carrier plate.
Do this by turning the engine with the crankshaft pulley nut and turning the torque converter. It is accessible through a hole in the cover.
- Install all screws loosely (6 x).
Tighten screws until heads are in contact with the carrier plate.
Tighten to 35 Nm (25.8 ft lb).
Use socket Torx TX 50.
NOTE: Remove the socket wrench from the crankshaft.
- Install nut onto right-hand side fender liner.
3. Lift engine and transmission
- Adjust lifting hook 999 5460 to the previously noted difference between the lifting beam and the spark plug covers.
See Removal, step 10.
- Ensure that the dip stick pipe is free of the fan and that that no hoses or cables are crimped.
4. Install bevel gear to transmission
- Ensure that mating surfaces on the transmission and bevel gear are clean.
- Install screws.
- Do not forget exhaust pipe bracket.
- First tighten the screws crosswise to light contact, then tighten to 50 Nm (36.9 ft lb).
- Install vibration damper, then torque to 25 Nm (18.5 ft lb).
- Install limiter on sub-frame, then torque to 50 Nm (36.9 ft lb).
5. Install propeller shaft to bevel gear
- Install propeller shaft, refer to Removal, step 22.
NOTE: If the bevel gear, flange etc. has been replaced: Install the propeller shaft in any position.
- Ensure that the propeller shaft and flange mating surfaces are clean.
- Use new screws when installing the propeller shaft.
Tighten screws crosswise to 8 Nm (5.9 ft lb), then tighten to 30 Nm (22 ft lb).
Start tightening with the same screw both times.
Use counterhold 999 5561, modified for clearance as required.
6. Install sub-frame to bodywork
NOTE:
- Use new screws (4 x M14).
- Lubricate screw threads.
- Take care that the left engine mounting does not damage the steering gear boot when the frame is lifted up.
- Commence on left-hand side.
Raise sub-frame on hoist.
Install frame and support plate bolts.
First tighten frame screws to 105 Nm then turn an additional 120° (77.4 ft lb plus 120°).
Then tighten the frame bracket screws to 50 Nm (36.9 ft lb).
Use a protractor 951 205a
Transfer mobile jack to right-hand side and repeat Procedure.
7. Remove:
- Lifting hook and lifting beam
- Lifting fork from the engine.
8. Install torque rod support onto the transmission.
NOTE: Use new screws.
- Tighten to 35 Nm then turn an additional 40° (25.8 ft lb plus 40°).
Use a protractor 9512050.
- Install screw for oil pipes bracket in the frame front edge.
Torque to 25 Nm (18.5 ft lb).
- Tighten front engine pad screw to 50 Nm (36.9 ft lb).
9. Install left engine mounting to sub-frame
- Torque to 50 Nm (36.9 ft lb).
10. Install left drive shaft
- Ensure that the ABS sensor pulse wheel on the drive shaft is free of contaminants.
- Press in drive shaft firmly so that the snap ring engages in its groove in the differential gear.
Check by pulling carefully on the drive shaft constant velocity joint.
NOTE: Take care not to damage the sealing rings in the transmission or drive shaft boot.
11. Continued installation of left drive shaft
NOTE: The following operations from this section: "Continued installation of left drive shaft", to section "Tighten left and right drive shaft nuts" should be carried out in order without interruption. This is so that the metal adhesive can cure in the correct way.
- Apply metal adhesive 1161370-0, to the drive shaft splines to the hub.
See illustration.
- Fold out and turn spring strut.
Align drive shaft with hub.
- Use holder 999 5563 to press down control arm.
Install drive shaft nut (the old nut can be reused.
Lubricate the nut) by hand.
- Remove holder.
NOTE: Take care not to damage the drive shaft boot.
Installing The Right Drive Shaft
12. Install drive shaft to transmission/bevel gear and support bearing mounting
- Install drive shaft to support bearing mounting.
Tighten bearing cover screws to the mounting to 25 Nm (18.5 ft lb).
13. Install drive shaft to hub
- Apply metal adhesive 1161370-0, to the drive shaft splines.
See the illustration inset in the right-hand corner.
- Fold out and turn spring strut.
Align drive shaft with hub.
- Install drive shaft nut (the old nut can be reused.
Lubricate the nut) by hand.
- Remove holder.
NOTE: Take care not to damage the drive shaft boot.
Installing Both Sides
14. Reinstall on both sides:
- Control arm/ball joint to axle shaft.
Remove socket 999 5562 from ball-joint.
Ensure that the ball joint pinion groove lines up with the screw hole in the stub axle.
Use new lock nuts on screws.
Torque to 50 Nm (36.9 ft lb).
- inks to anti-roll bar.
Use new locknuts.
Torque to 50 Nm (36.9 ft lb).
- Tie rods.
Use new locknuts.
Torque to 70 Nm (51.6 ft lb).
15. Tighten left and right drive shaft nuts
- Use counterhold 999 5540 and protractor 9512050.
Tighten to 120 Nm then turn an additional 60° (88.6 ft lb plus 60°).
- Remove counterhold.
16. Install:
- The bracket to the brake pipe/ABS line (both sides)
- ABS sensor in stub axle, both sides. Clean the sensor with a soft brush.
NOTE: Ensure that the sensor seat is absolutely clean.
- Tighten sensor to 10 Nm (7.38 ft lb).
- Install plastic nuts (both sides) for the fender liners.
Right-Hand Drive Car
17. Install steering shaft joint on steering gear
- Check that the bearing in the lower steering shaft boot is in position.
- Locate and slide the steering shaft joint in the boot and onto the steering gear pinion,
- Install steering shaft joint and steering gear screw.
Use a new locknut.
Slide the joint up the steering gear pinion as much as possible before tightening.
Tighten nut to 20 Nm (16.2 ft lb).
Install locking shackle.
- Install joint to the lower steering shaft inside the car
- Use new screw and locknut.
Torque to 30 Nm (22 ft lb).
NOTE:
- The steering gear position must not be changed so that the pinion is turned a revolution.
- The SRS-system contact reel can be damaged if this occurs.
18. Install collision protection on steering gear
- Tighten screws to 80 Nm (59.0 ft lb).
Left And Right-Hand Drive Cars
19. Install:
- Mounting screw (c) to the cable conduit on the sub frame
- Carbon filter reservoir.
Clamp the hoses (A) to the sub-frame.
Use a tie strap.
- Connector (B) to the accelerometer.
- Tighten exhaust pipe clamp.
"Twist" the pipe when tightening.
20. Install:
- Front splash guard.
Press the front edge into place.
Press forward and press upward at rear so that guide spigot is seated in slot.
Install screws.
- Wheels.
Left-Hand Drive Car
21. Install steering shaft to steering gear and steering column
- Check that the bearing in the lower steering shaft boot is in position.
- Align steering shaft joint in boot and to steering gear pinion.
- Install steering shaft joint and steering gear screw.
Use a new locknut.
Slide the joint up the steering gear pinion as much as possible before tightening.
Tighten nut to 20 Nm (16.2 ft lb).
Install locking shackle.
- Install joint to the lower steering shaft inside the car.
Use new screw and locknut.
Torque to 30 Nm (22.0 ft lb).
Left And Right-Hand Drive Cars
22. Install screws between transmission/engine and transmission/starter motor
- Tighten transmission/engine screws (3 x) to 50 Nm (36.9 ft lb) and transmission/starter motor screws (2 x) to 40 Nm (29.5 ft lb).
- Install:
Ground lead to transmission
Cable duct on transmission
Heated oxygen sensor (H02S) connector (-section) on the bracket
Dip stick pipe.
Use a new O-ring.
Torque to 25 Nm (18.5 ft lb).
Cable harness clamp on dip stick bracket.
23. Install:
- Ground strip on firewall
- Torque control arm/torque rod screw.
Use new screw and nut.
Tighten to 35 Nm then turn an additional 90° (25.8 ft.lb plus 90°).
- Charge air pipe between turbocharger (TC) and charge air cooler (CAC).
Tighten the pipe mounting to the torque control arm stay to 25 Nm (18.5 ft lb).
Use a new locknut.
- Charge air pipe-intake manifold
- Throttle cable and cover
- Upper engine oil cooler hose.
24. Install:
- Clamps/clamps for the cable harness/ground lead
- Transmission connector (do not forget seal)
- Oil cooler hoses
- Hoses to EGR Exhaust Gas Recirculation Valve (only cars with EGR).
- Adjust the gear selector cable and install to transmission.
25. Install:
- Expansion tank
- Battery shelf
- Turbocharger (TC) intake
- Air cleaner (ACL) housing with fresh air hose and connections
- Turbocharger (TC) control valve to air cleaner (ACL) housing battery.
Finishing Work
26. Check transmission oil level
- Refer to steps 29 through 33 below.
NOTE:
- Use only automatic transmission fluid which fulfills both Dexron II E and Ford Mercon standards.
- When fluid and transmission are cold and the engine is off, correct oil level is only a few mm up the dipstick.
27. Checking diagnostic trouble codes (DTCs)
- Check and erase diagnostic trouble codes (DTCs), refer to Powertrain Management.
28. Test drive
- Test drive the car with driving programs in all three position (S, E and W).
NOTE:
- Check that no diagnostic trouble codes (DTCs) have been stored during the test drive.
- Erase diagnostic trouble codes (DTCs).
29. Checking oil level
- Conditions
The difference between MAX and MIN volume is 0.5 liter (0.53 US qt.).
Check oil temperature in transmission.
At room temperature (+20°C (+68.0°F)) the oil level is near the MIN mark on the "cold area".
At the room temperature (+20°C (+68.0°F)) and low oil level the oil only just reaches the dipstick.
"Cold area" (+40°C (+ 104.0°F)) is reached after the engine has been idling for approximately 15 minutes in the workshop.
"Warm area" (+80°C (+176.0°F)) is reached after approximately 30 minutes road use with an air temperature over +15°C (+59.0°F).
NOTE: The check should be carried out at an oil temperature of +80°C. (+176.0°F)
30. Preparations:
- Park car on level surface
- Set the parking brake
- Apply the foot brakes
- Engine idling
- Move gear selector lever to position P.
31. Move the gear selector through all positions, stopping in each position for approximately 3 seconds
- Return gear selector to position P.
Wait 2 minutes before checking oil level.
The dipstick must be pushed down completely in the dipstick tube.
CAUTION:
- Wipe the dipstick with a nylon cloth or similar.
- A cloth that does not leave traces of lint or threads on the dipstick.
Low Level (Topping Up)
32. Top up with oil through the dipstick pipe
- Take account of the temperature when topping up with oil.
See step 29 above.
High Level (Overfilling)
NOTE:
- The oil may be very hot if the car has just been driven.
- Avoid skin contact with transmission fluid.
- The transmission must not be operated if the oil level is too low.
- This can cause increased operating temperatures and oil leakage.
33. Drain the oil
- Undo the drain plug.
Allow some of the oil run out.
Install plug.
Torque to 40 Nm (29.5 ft lb).
- Check the level taking account of temperature.
See step 29 above.
- The oil can also be sucked out through the dipstick pipe using an oil suction syringe with a narrow gauge hose.
NOTE: Strict cleanliness is important.
34. Return transmission. (Only when replacing entire transmission assembly)
- Returning the old transmission unit.
In order to accurately analyze the transmission fault, information is required about all symptoms which have caused the unit to be replaced. This information should be reported on the "Diagnosis and Check List" form which has been prepared. Make sure form has been filled out accurately.
Note clearly all fault symptoms under the heading "Customer Complaints". Fill in the results after test driving the car.
Place completed form in a plastic folder behind the torque converter so that it will not fall out.
The different sections of the form are to be used as follows:
1. The white copy goes with the transmission.
2. The yellow copy is sent to the respective importer.
3. The pink copy is kept by the issuing party.