Replacement
U. Transmission, replace
Special tools: 999 5006, 5033, 5045, 5186, 5460, 5461, 5462, 5463, 5488, 5534, 5540, 999 5562, 5563, 5972, 998 5972, 951 0030, 2050, 115 8147
Important! Avoid skin contact with transmission fluid!
The methods described apply to all engine variants. The illustrations show mainly the B5234T Turbo engine in its early and later versions. The illustrations show the right-hand drive variant only when there are differences in the working method from a left-hand drive.
U1
Adjust steering wheel position
Slacken wheel adjusting lever.
Press wheel forward into bottom position and angle upward as far as possible Lock wheel in position with lever.
Move gearshift selector to position N.
U2
Remove:
- Battery
- Battery shelf
- Air cleaner housing ACL complete with inlet pipe.
Detach timing valve from ACL housing. (Only cars with Turbo engines.)
U3
Only cars with Turbo engines, early versions:
Remove clamp from charge air pipe. Remove hose from pipe.
Remove:
- Air intake pipe (from ACL) to Turbocharger
- Cover over the control pulley.
Remove:
- Pipe to throttle body. keep pipe to one side with a tie strap
- The upper oil cooler hose to the engine radiator.
Seal all openings to oil connections with plastic plugs.
See also U6.
U4
Only cars with Turbo engines, late versions:
Remove:
- Cover over the control pulley. Detach throttle cable from control pulley and bracket
- Charge air pipe between Turbocharger (TC) and radiator. Loosen bracket at the torque arm support. Reinstall nut on support
- Air intake pipe (from ACL) to Turbocharger.
U5
Remove:
- Charge air pipe to throttle body (TB)
- The upper oil cooler hose to the engine radiator.
Seal all openings to oil connections with plastic plugs.
Keep the lower pipe to the charge air cooler to one side with a tie strap.
U6
Remove:
- Transmission cable from transmission
- Connector from transmission. Remember rubber seal.
- Cable clamps retaining ground lead/cable harness to the transmission or sub-frame.
NOTE: The fastening points may vary for different model years.
Early type:
- Transmission vacuum hose from clip.
Late model:
- Detach/unclip the cable conduit from the transmission
- Detach the HQ2S connector/connectors from the bracket on the transmission.
U7
Detach hoses leading to transmission oil cooler.
Inlet hose connected to cooler upper quick-coupling and oil return hose to transmission.
Remove oil dipstick pipe.
Seal all openings with plastic plugs
Cars with (EGR) Exhaust Gas Recirculation System:
Detach hoses from the converter.
U8
Loosen nut to the rear engine mounting cushion.
Remove:
- Remove the screws between the engine - transmission and transmission - starter motor (5 screws).
Lift radiator overflow tank from mounting and let it lie loose.
U9
Detach ground plate from firewall.
Remove screws on upper torque rod - torque arm at engine.
Install lifting yoke 9995534 to torque rod/engine.
U10
Install:
- Support rails 999 5033 to fender (wing) edges.
- Lifting beam 999 5006 to supports.
Locate the beam directly above the eye on the yoke.
- Lifting hook 999 5460.
NOTE: When using the early type of lifting hook (A) the hook 9995166 must be connected between the lifting fork and the lifting hook. Lifting hook, late versions(B).
Tighten the hook approx. 5 mm (0.2") to relieve engine mounts slightly.
- Measure and record the distance between lifting beam and spark plug cover.
U11
Remove:
- Front wheels
- ABS sensor from stub axle (left side)
NOTE: Do not separate the connector halves.
Remove:
Brake line and ABS cable brackets (both sides). Detach the brackets and let them hang loose.
U12
Remove:
- The two front plastic nuts for the inner guards (both sides) and the two Torx screws on the left-hand side (early version).
- Left drive shaft nuts.
Free the nuts of the locking tabs. (Only applies to early versions.) Install counterhold 999 5461 (4 wheel studs) or 999 5540 (5 wheel studs). Remove nut.
Detach drive shaft end in the hub.
Knock the drive shaft end in the hub approx. 10-15 mm (0.4-0.6"). Use a plastic or copper hammer.
U13
Remove:
- Front splash guard, both screws.
Press the splash guard forwards to free the retainers at the rear edge or the panel. Detach the guard at the front and remove it.
- Splashguard under the engine. (Early type)
U14
Remove link/ball joint from stub axle (both sides)
Attach protective sleeves 999 5562 on the ball joints (both sides).
Disconnect links from anti-roll bar.
U15
Remove:
- Mounting screw for cable conduit on sub-frame, and unhook from the sub-frame.
Undo the EVAP canister with its hoses from the subframe.
Cut tie securing hoses and hang canister on body.
Loosen exhaust pipe clamp behind the catalytic convertor.
U16
Remove
- Oil pipe bracket screws
- The two bolts securing torque rod mounting support on transmission.
Drain transmission oil.
NOTE: Only if the transmission or oil is to be replaced. Drain plug torque: 40 Nm (30 ft.lbs).
Caution! Oil may be extremely hot
U17
Right-hand drive models only:
Remove crash guard over the steering gear (2 screws).
U18
Detach right drive shaft
Remove bearing cap. Pull out interior section of drive shaft and at the same time fold out spring strut.
NOTE: Ensure the seal in the transmission is not damaged.
Reinstall seal plug 999 5488 in transmission.
Let drive shaft rest against sub-frame. Tape drive shaft end to pipe bends.
Right-hand drive models only:
Let the drive shaft end rest temporarily against the oil pipe.
U19
Remove front engine mountisub-frame screw
Undo the screw on the engine mount/steering gear approx. one turn.
Remove the mounting nuts which fasten the steering gear to the sub-frame (5 nuts).
Right-hand drive models only:
Remove the nut (A) on the crash guard sub-frame
U20
Remove sub-frame from car.
Place hoist 998 5972, using a light pressure, as a support beneath left side of sub-frame.
Remove sub-frame support bracket screws in the body (both sides).
Unscrew the two screws between the frame and body (right side) approx. 15 mm (0.6").
Remove bolts on left-hand side.
U21
Right-hand drive models only:
Lower sub-frame approx. 100 mm (4").
Ensure that steering gear studs (five) and crash guard plate studs are clear of the frame.
Remove the screws on the anti-roll bar bearing cap (left). Slacken bolts on right-hand side until held by just a few threads.
Tie the anti-roll bar up on the steering gear, as shown in the illustration.
U22
Lower sub-frame.
NOTE: Check that the screws on the steering gear come free from the sub-frame. Make sure that the link is free from the drive shaft boot on the right side.
Remove the engine hoist.
Let the sub-frame hang free on the screws on the right.
Right-hand drive models only:
Tape up the rear side of the drive shaft end to the oil
pipe.
Remove ground cable from transmission.
U23
Hang up the steering gear with hook 9995045 from the hole on the frame member flange.
Illlustration to the right shows a right-hand drive car.
Remove the screws on the steering gear, engine mount and the nut on the top side of the engine mount. Remove engine mounting cushion.
NOTE: Make sure that the steering gear hangs securely on the hook so that the lower steering shaft does not slide out from the steering column.
U24
Loosen:
- The clamps for the heated oxygen sensor (HO2S) cable from cover over engine mount.
- Connector and cable for vehicle speed sensor (VSS).
Remove:
- Cover at rear engine mounting.
- Rear engine mounting from transmission.
U25
Remove left drive shaft
Rotate and fold out spring strut. Tap on the drive shaft end with a plastic or copper hammer and pull drive shaft out of the hub. Remove drive shaft from transmission. Use disconnecting tool 999 5462 between the transmission and the inside of dnve shaft.
NOTE: Take care that the seal rings in the transmission and the boot on the drive shaft are not damaged.
Reinstall seal plug 999 5488 in transmission.
Clean off traces of metal adhesive from the spline joint (hub-drive shaft).
U26
Lower engine and transmission
Lower using lifting hook until the distance between the frame and the spark plug cover is approx. 320 mm (12.5").
NOTE: If the enqine is lowered too much, the exhaust pipe can press the steering gear down.
NOTE: Make sure wires and hoses are not pinched or stretched and that the engine dipstick is free from the fan.
U27
Attach universal tool 999 5972 and transmission fixture 9995463 to hoist.
Attach the transmission fixture to the tmnsmission using the screws from the torque red retainer.
At the same time, fit bearing plate (marked 999 5463-1) on fixture. Apply hoist using light pressure.
U28
Remove torque converter screws (6 screws).
Use Torx TX5O socket (early models TX4O).
Remove the lower plastic nut and bend out the right inner fender. Rotate crankshaft using socket wrench.
Remove the screws between the engine and transmission (7 screws).
U29
Remove transmission
Make sure torque converter is removed with transmission and does not slide off stator shaft. Use hole in torque converter cover to press the torque converter down. See illustration on left.
NOTE: Do not prise toward carrier plate increment rim for the flywheel sensor.
U30
Remove oil pipe with hose from transmission
Rinse pipe and hose with Dexron II E/Ford-Mercon ATF oil.
Attach oil pipe to new transmission
Place a new 0-ring on the quick-coupling.
U31
Flush oil cooler with ATF
Attach a hose to upper cooler connection.
Place a container beneath the return hose. Flush with ATF- as above.
U32
Make sure carrier plate is not damaged or cracked
Make sure:
- contact surfaces between the transmission and engine are clean, and that guide bushings are not faulty and are in place.
- bushings for torque converter in crankshaft are not faulty.
U33
Make sure contact surfaces on torque converter are clean
Apply a light coating of grease to torque converter guide studs and in the holes for the guide sleeves on the torque converter cover.
Make sure torque converter is as far into the transmission as possible.
Check with a ruler. The distance between the cover and retaining tabs should be approximately 14 mm (0.55').
U34
Install transmission
Use transmission fixture to adjust the height and angle.
Fit transmission into engine.
Reinstall screws (seven screws). Tighten alternately to a light pressure. Then tighten the screws.
Torque: 50 Nm (37 ft. lbs)
CNOTE: Check carefully during tightening that the guide sleeves locate correctly in their guide holes and that the torque converter cover is contact with the engine before torque tightening.
Remove fixture and hoist from transmission.
U35
Install torque converter screws
NOTE: Use new bolts, Torx TX5O.
Fit torque converter to carrier plate by turning engine with the crankshaft pulley nut. Then rotate the torque converter (accessible through cover opening, see picture on left).
Loosely insert all six screws. Screw until heads are against the carrier plate. Torque to 35 Nm (26 ft. lbs). Use Torx TX 50 socket (early models TX4O must be changed to TX5O).
NOTE!: Remove the socket wrench from the crankshaft.
U36
Raise engine and transmission
Screw lifting hook 9995460 up to the measurement noted earlier between the lifting beam and the spark plug cover. See U10.
Make sure the dip stick pipe is clear of the fan and that hoses or wires are not pinched.
U37
Install the rear engine mounting on the transmission
Install the mounting on the transmission (3 screws).
Tighten the rearmost two. Torque: 50 Nm (37 ft. lbs).
Remove the front screw.
Install the cover using the mounting screw.
Press the cover up against the mounting and tighten the screw.
Torque: 50 Nm (37 ft. lbs)
U38
Install the engine mount, using a new nut.
Guide the engine mount location dowel into the cover. Put the nut on loosely.
Install the screw for the steering gearlengine mount
Do not tighten the screw
Remove support hook 9995045.
Install:
- Heated oxygen sensor (HO2S) cable with clamps on cover.
- Connector and cables for vehicle speed sensor (VSS)
- Ground cable to transmission
U39
Right-hand drive models only:
Remove the tape from the drive shaft and let the shaft rest on the oil pipe.
Raise sub-frame to approx. 100 mm (4") from the body. Position steering gear on right side and crash guard in sub-frame. Reinstall screws to anti-roll bar left bearing cap and tighten both bearing caps.
Torque: 50 Nm (37 ft. lbs)
U40
Reinstall sub-frame.
NOTE: Use new screws, tour M14 screws. Grease the screw threads. Be careful to align the steering gear screws against the frame!
Commence on left-hand side. Raise sub-frame on hoist.
Install frame and support plate bolts. Tighten sub-frame bolts first to 105 Nm (77.5 ft. lbs)+ 120° and then support plate bolts to 50 Nm (37 ft. lbs). Use protractor gauge 9512050. Transfer hoist to right-hand side and repeat procedure.
U41
Remove:
- Remove lifting hook, lifting beam and support rails.
- Lifting fork from the engine.
Torque nut on the rear engine mounting cushion.
Torque: 50 Nm (37 ft. lbs).
U42
Install:
- Steering gear nuts (five). Use new nuts!
Torque: 50 Nm (37 ft. lbs).
- Nut on crash guard/sub-frame (A). Right-hand drive models only: Torque: 50 Nm (37 ft. lbs)
- Screw for sub-frame - front engine mounting.
Tighten the screws on the front and rear engine mounting.
Torque: 50 Nm (37 ft. lbs).
U43
Install:
- Torque rod support's fastening in the transmission.
NOTE: Use new bolts.
Tightening torques:
Late version M10, 35 Nm + 40° (26 tt.lbs).
Early version with M8 screw: 18 Nm (13 ft. lbs) + 90°. Use protractor gauge 9512050.
- Screws on oil pipe brackets.
Torque: 25 Nm (19 ft. lbs)
Tighten exhaust pipe clamp.
Wiggle the pipes during tightening.
U44
Install right drive shaft
NOTE: Make sure that the seal rings in the transmission and the gaiter on the drive shaft are not damaged.
Replace bearing cap.
Torque: 25 Nm (19 ft. lbs)
U45
Right-hand drive models only:
Replace crash guard above steering gear.
2 screws. Torque to: 80 Nm (59 ft. lbs).
U46
Install left drive shaft.
Ensure that the ABS sensor pulse wheel is free from dirt.
Press the drive shaft in firmly so that it locks securely with its lock ring on to the differential gear groove. Check by pulling carefully on the drive shaft CV housing.
NOTE: Make sure that the seal rings in the transmission and the boot on the drive shaft are not damaged.
U47
Apply metallic adhesive 1161370-0 on the drive shaft splines to the hub as in picture.
Fold out and rotate spring strut and fit the drive shaft into the hub.
Use holder 999 5563 to hold the link down.
Replace drive shaft nut by hand.
Early type (M20): Use a new oiled nut.
Late model (M22): The old nut can be reinstalled. Oil the nut.
Remove retainer. NOTE! Take care that the drive shaft boot is not damaged.
U48
Install on both sides:
- Link/ball joint to stub axle. Remove socket 999 5562 from ball joint. Make sure the ball joint spindle's groove lines up with the screw hole in the stub axle. Use new lock nuts on bolts.
Torque: 50 Nm (37 ft. lbs)
- Link to anti-roll bar. Use new lock nuts.
Torque: 50 Nm (37 ft. lbs).
U49
Tighten left drive shaft nut
Use counterhold 999 5461 (4 wheel studs) or 999 5540
(5 wheel studs) and protractor 951 2050. Torque to 120 Nm (89 ft. lbs) + 60°.
Remove counterhold.
Lock nuts, early type (M20): knock the nut locking flange down in the groove on the drive shaft.
Lock nut, late model (M22): The lock is self-locking.
U50
Install:
- Brake hose/ABS cable bracket (both sides).
- ABS sensor on wheel spindle. Clean the sensor with a soft brush.
NOTE: Make sure that the sensor seating is absolutely clean.
Tighten sensor. Torque: 10 Nm (7.4 ft. lbs)
- Plastic nuts (both sides) and Torx screws in inner fender liners (left side, early model).
U51
Install:
- Cable conduit on sub-frame.
- Evaporative Emission Canister. Clamp hoses with tie straps to the sub-frame. Secure hoses in the sub-frame.
- Cover under engine. (Early type)
U52
Install:
- The front cover. Press into position at front. Press forward and press upward at rear so that guide spigot is seated in slot. Install screws.
- Wheels. Lubricate the hub center location dowel for the rim with rust inhibitor 1161030-0. lighten the studs lightly. Torque diagonally. lightening torque: 110 Nm (81 ft.lbs).
NOTE! See also Specifications, Tightening torques. Mechanical Specifications
U53
Reinstall the screws between the engine - transmission and transmission - starter motor.
NOTE: Bracket for the cooler hose. (Early versions).
Transmission - motor (3 screws), torque: 50 Nm (37 ft.lbs)
Transmission - starter motor (2 screws), torque: 40 Nm (30 ft.lbs)
Install:
- Cable conduit on the transmission (Late versions)
- HO2S connector (connectors) in the bracket (late version)
- Oil dipstick pipe with new 0-ring. Torque: 25 Nm (19 ft. lbs)
U54
Install:
- Clamp/clamps for wiring harness/ground cable
- Connector to transmission (Note! the seal)
- Oil cooler hoses
- Breather hose from transmission to clamp/mounting (early versions).
- Hoses to (EGR) Exhaust Gas Recirculation Valve (only cars with EGR)
Adjust the gear change cable and fit it on the transmission.
Refer to section; Gear change cable, replace/adjust, procedures L9-L12. L. Transmission Cable, Replacement/Adjustment
U55
Install:
- Ground connection on firewall.
- Screw and nut for torque arm/torque rod.
NOTE: Use new screw and locknut.
Replacement part number lock nut P/N:
- M8 (on early version) 948 645-7
- M1O (on late version) 971 098-9
NOTE: On later version the lock nut is standard.
Tighten to
- M8 18 Nm (13ft.lbs)+120°
- M1O 35 Nm (26 ft.lbs) +90°.
U56
Only cars with Turbo engines, early version:
Install:
- Hose to engine oil cooler
- Intake pipe to throttle body
- Intake pipe to Turbocharger
- Hose to charge air pipe over engine.
- Cover over the control pulley.
U57
Only cars with Turbo engines, late version:
Install:
- Hose to engine oil cooler
- Intake pipe to throttle body
Remove the tie strap holding the lower pipe to the charge air cooler CAC.
U58
Install:
- Pipe from the turbocharger to the CAC. Tighten nuts on pipe mounting in the torque arm rod.
Torque: 25 Nm (19 ft. lbs)
- Throttle cable to control pulley and locking clip in cable adjuster.
- Cover over the control pulley.
- Intake pipe to Turbocharger
U59
Install:
- Expansion tank
- Battery shelf
- ACL with intake manifold and connections
- Timer valve to ACL housing (Only cars with Turbo engines.)
- Battery
Reset steering wheel position.
U60
Check transmission oil level.
See H1-H5. H. Oil Inspection
NOTE: Only ATF oil which meets demands for both Dexron II E and Ford Mercon.
NOTE: When oil and transmission are cold and the engine is off, correct oil level reaches only a few mm (in.) up the dipstick.
U61
Check that DTCs have been cleared.
See section On-board Diagnostic System, Diagnostic Test Mode 1. Testing and Inspection
U62
Test drive with mode selector in all three positions (E, W, S)
U63
Check oil level when transmission and oil are hot
The gear selector should be in position P and the engine idling.
At room temperature (+20°C=68°F) the oil barely reaches the dipstick. "The Cold range"
The "cold range" (+40°C=104°F) is reached after approximately 5 minutes of idling, while the "hot range" (+80°C=176°F) is reached after approximately 30 minutes of highway driving at an ambient temperature of +15 °C (59 °F).
See also operation H4. H. Oil Inspection
U64
After test driving check that no DTCs have been posted using DTM 1.
See section On-board diagnostic systems. Testing and Inspection
U65
Returning the old transmission unit
To be able to accurately analyze the transmission fault, information is required on all symptoms which have motivated the replacement of the unit. This information should be reported on the "Diagnosis and Check List" form which has been prepared. Testing and Inspection
Make sure the form has been filled out accurately
Write clearly all fault symptoms under the heading "Customer Complaints". After test driving, fill in the results.
Place completed form in a plastic folder behind torque converter so that it will not fall out. The difterent 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.