SECTION 308-03C: Manual Transmission/Transaxle Vehicles With: MT285

2002 Focus Workshop Manual

INSTALLATION

Procedure revision date: 11/14/2002


Transaxle

 

Special Tool(s)

Support Bar, Engine
303-290A

Adapter for 303-290A
303-290-01

Adapter for 303-290A
303-290-02

Adapter for 303-290A
303-290-03A

 

General Equipment

Transmission jack

Retaining straps

 

Material

Anti-seize grease

SAM-1C9107-A

1.       Using a suitable transmission jack, install the transaxle.

2.       Install the transaxle left-hand retaining bolts.

3.       Remove the transmission jack.

         Remove the retaining straps from the transaxle.

4.       Install the transaxle right-hand retaining bolts.

5.       Attach the starter motor to the transaxle.

6.       Lower the vehicle.

7.       Install the engine rear mount bracket.

8.       Using the special tools, raise the engine and transaxle assembly.

9.       NOTE: Install a new engine rear mount center retaining nut.

NOTE: Do not tighten the engine rear mount retaining nut at this stage.

Install the rear engine mount.

10.   Remove the special tools.

11.   Raise and support the vehicle. For additional information, refer to Section 100-02 .

12.   Install the accessory drive belt cover.

13.   Connect the vehicle speed sensor (VSS) electrical connector.

14.    CAUTION: Support the halfshaft. The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.

 CAUTION: Do not damage the halfshaft oil seal.

 CAUTION: Make sure the snap ring is correctly seated.

NOTE: Install a new snap ring.

Attach the left-hand halfshaft to the transaxle.

15.    CAUTION: Support the halfshaft. The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.

 CAUTION: Do not damage the halfshaft oil seal.

NOTE: Install a new halfshaft center bearing cap and locknuts.

Attach the right-hand halfshaft and the intermediate shaft to the transaxle.

         Install the center bearing cap.

16.   Attach the gearshift cables to the transaxle.

1.       Attach the retaining bracket to the transaxle.

2.       Attach the gearshift cable and the selector cable to the selector levers.

17.   Coat the exhaust flexible pipe studs with Anti-seize grease.

18.   NOTE: Install a new gasket and new nuts.

NOTE: Support the catalytic converter with a suitable transmission jack.

Attach the catalytic converter to the exhaust manifold.

         Attach the heated oxygen (HO2S) sensor to the catalytic converter.

19.   Install the catalytic converter bracket.

         Attach the catalyst monitor sensor to the catalytic converter.

20.   NOTE: Install a new gasket and new nuts.

Attach the exhaust flexible pipe to the tailpipe and muffler assembly.

21.    CAUTION: Do not excessively bend or twist the exhaust flexible pipe. Failure to follow this instructions may cause damage to the exhaust flexible pipe.

Remove the transmission jack.

22.   Connect the reversing light switch electrical connector.

23.   Install the crossmember. For additional information, refer to Section 502-00 .

24.   Tighten the strut and spring assembly upper mounting retaining nuts on both sides.

25.   Connect the clutch slave cylinder supply line to the transaxle.

         Install the clip.

26.   Attach the electrical connector to the transaxle.

27.   Install the starter motor retaining bolts.

         Attach the ground cable to the transaxle.

28.   Install the transaxle upper retaining bolts.

29.   Tighten the engine rear mount retaining nuts.

30.   Install the air cleaner intake pipe. For additional information, refer to Section 303-12 .

31.   Install the battery tray. For additional information, refer to Section 414-01 .

32.   NOTE: The gearshift lever must rest in the shift passage third and fourth gear.

Adjust the gearshift cables. For additional information, refer to Section 308-00 .

33.   Bleed the clutch system. For additional information, refer to Section 308-00 .

34.   Check the transmission fluid level and top up with manual transmission fluid if necessary. For additional information, refer to Transaxle Draining and Filling in this section.