Transmission - 2.0L Duratec-HE

WARNING: This page is about a different variant/trim than selected.

SPECIAL TOOL(S) / GENERAL EQUIPMENT

	205-775 Protector, Halfshaft Seal
	303-290-01 Adapter for 303-290A TKIT-1999A-F/LT TKIT-1999A-FM/FLM TKIT-1999A-LM
	303-290-03A Adapter for 303-290A
	303-290B Support Bar, Engine
Ford Diagnostic Equipment
Transmission Jack
Cable Ties
Retaining Strap
Wooden Block

MATERIALS SPECIFICATIONS

Name	Specification
High Temperature Nickel Anti-Seize Lubricant XL-2	-

WARNING: Before beginning any service procedure in this service information, refer to Safety Warnings in SERVICE INFORMATION General Information. Failure to follow this instruction may result in serious personal injury.

Refer to: HEALTH AND SAFETY PRECAUTIONS .

WARNING: Make sure that the engine and transmission assembly is on wooden blocks and secured with suitable retaining straps.

NOTE: Make sure that the mating faces are clean and free of foreign material.

NOTE: Take extra care not to damage the wiring harnesses.

NOTE: Make sure that the locating dowels remain installed.

NOTE: Make sure that no components catch.

Fig 1: Supporting Transmission Using Transmission Jack

Courtesy of FORD MOTOR CO.

Support the transmission using the transmission jack.
General Equipment : Wooden Block

General Equipment : Retaining Strap

General Equipment : Transmission Jack
NOTE: Make sure that the installation marks are aligned.

NOTE: Make sure that the component is correctly located on the locating dowels.

NOTE: Make sure that the component is installed to the position noted before removal.

Fig 2: Installing Transmission Using Transmission Jack
Courtesy of FORD MOTOR CO.

NOTE: Tighten on both sides simultaneously.

Fig 3: Inspecting Transmission Housing

Courtesy of FORD MOTOR CO.

Tighten each bolt 1 turn at a time.
Torque : 48 Nm
Torque : 48 Nm

Fig 4: Locating LH Transmission Housing Bolts
Courtesy of FORD MOTOR CO.
Torque : 48 Nm

Fig 5: Locating RH Transmission Housing Bolts
Courtesy of FORD MOTOR CO.
Torque : 48 Nm

Fig 6: Locating Transmission Housing Stud Bolt
Courtesy of FORD MOTOR CO.
Torque : 25 Nm

Fig 7: Locating Transmission Cable Bracket Nut
Courtesy of FORD MOTOR CO.
Lower the vehicle.
Torque : 48 Nm

Fig 8: Locating Clutch Motor Housing Bolts
Courtesy of FORD MOTOR CO.
Torque : 80 Nm

Fig 9: Locating Clutch Motor Panel Bracket Bolts And Nut
Courtesy of FORD MOTOR CO.
Torque : 15 Nm

Fig 10: Locating Clutch Motor Panel Bracket Nut
Courtesy of FORD MOTOR CO.
Fig 11: Inspecting Clutch Motor Panel Bracket Studs
Courtesy of FORD MOTOR CO.

NOTE: Make sure that a new bolt is installed.

Fig 12: Locating Clutch Motor Panel Bolt

Courtesy of FORD MOTOR CO.

Torque : 148 Nm
Remove the Special Tool(s) : 303-290B (Support Bar, Engine), 303-290-01 (Adapter for 303-290A) , 303-290-03A (Adapter for 303-290A)

Fig 13: Identifying Special Tools 303-290B (Support Bar, Engine) 303-290-01 (Adapter For 303-290A) 303-290-03A (Adapter For 303-290A)
Courtesy of FORD MOTOR CO.
Torque : 80 Nm

Fig 14: Locating Halfshaft Bracket Bolts
Courtesy of FORD MOTOR CO.

NOTE: Make sure that new nuts are installed.

NOTE: Only rotate the crankshaft counterclockwise.

Fig 15: Rotating Crankshaft Counterclockwise

Courtesy of FORD MOTOR CO.

Use a magnetic socket
Torque :

Stage 1: 5 Nm

Stage 2: 25 Nm
Fig 16: Installing Crankshaft Side Gear Panel
Courtesy of FORD MOTOR CO.
NOTE: Make sure that a new component is installed.

Fig 17: Locating Exhaust Flexible Pipe Gasket
Courtesy of FORD MOTOR CO.
NOTE: Make sure that the exhaust flexible pipe is not forcibly bent or twisted.
1. Apply a thin coating.
  Material : High Temperature Nickel Anti-Seize Lubricant / XL-2
2. Torque : 48 Nm
Fig 18: Locating Exhaust Flexible Pipe Gasket Nuts
Courtesy of FORD MOTOR CO.
Torque : 24 Nm

Fig 19: Locating Turbocharger Bracket Bolts
Courtesy of FORD MOTOR CO.
Remove the following items:
- General Equipment : Cable Ties
Fig 20: Identifying Exhaust Flexible Pipe Cable Ties
Courtesy of FORD MOTOR CO.

NOTE: Take extra care not to damage the edges of the component.

Fig 21: Checking Halfshaft Seal Protector

Courtesy of FORD MOTOR CO.

Remove the special tool before completely installing the halfshaft.
Special Tool(s) : 205-775 (Protector, Halfshaft Seal)
Install the following items:
1. NOTE: Make sure that a new component is installed.
  
  NOTE: Make sure that the components are installed to the position noted before removal.
2. Torque : 6 Nm
3. Torque : 6 Nm
4. Torque : 25 Nm
5. Torque : 25 Nm
Fig 22: Locating Halfshaft Clamp Nuts
Courtesy of FORD MOTOR CO.
On both sides.

Fig 23: Locating Lower Arm Tie Strep
Courtesy of FORD MOTOR CO.
Fig 24: Installing Lower Arm
Courtesy of FORD MOTOR CO.
Torque : 83 Nm

Fig 25: Locating Lower Arm Knuckle Bolt
Courtesy of FORD MOTOR CO.
Torque : 24 Nm

Fig 26: Locating Hose Bracket Bolt
Courtesy of FORD MOTOR CO.
If equipped.
Torque : 8 Nm

Fig 27: Locating Cable End Bracket Bolt
Courtesy of FORD MOTOR CO.
Refer to: FRONT HALFSHAFT LH .
Refer to: Transmission Fluid Level Check .
Fig 28: Locating Engine Lower Cover Bolts
Courtesy of FORD MOTOR CO.
Fig 29: Locating Engine Lower Strip Bolts
Courtesy of FORD MOTOR CO.
Lower the vehicle.
Torque : 35 Nm

Fig 30: Locating Selector Lever Cable Bracket Bolts
Courtesy of FORD MOTOR CO.
NOTE: Gearshift cables must not be kinked or bent.

NOTE: Take extra care when handling selector lever cable.

Fig 31: Installing Selector Lever Cable Bracket
Courtesy of FORD MOTOR CO.
Refer to: SELECTOR LEVER CABLE ADJUSTMENT .
WARNING: Make sure that the wiring harnesses are correctly located.

NOTE: Take extra care not to damage the wiring harnesses.

Fig 32: Installing TCM Electrical Connector
Courtesy of FORD MOTOR CO.
Fig 33: Installing TCM Electrical Connector Handle
Courtesy of FORD MOTOR CO.

WARNING: Make sure that the wiring harnesses are correctly located.

Fig 34: Locating Transmission Assembly Retainer Bolts

Courtesy of FORD MOTOR CO.

Torque : 35 Nm
Torque : 15 Nm

Fig 35: Locating TCM Electrical Wiring Harness Clip And Bracket Nuts
Courtesy of FORD MOTOR CO.
Fig 36: Locating TCM Electrical Wiring Harness Clip
Courtesy of FORD MOTOR CO.
Torque : 48 Nm

Fig 37: Locating Cowl Panel Grille Cover Nuts
Courtesy of FORD MOTOR CO.
1. Torque : 8 Nm
2. Torque : 15 Nm
Fig 38: Identifying Cowl Panel Grille Cover Bolts
Courtesy of FORD MOTOR CO.
Refer to: BATTERY .
Refer to: AIR CLEANER .
Refer to: COWL PANEL GRILLE .
Fig 39: Installing Cowl Panel Grille Cover
Courtesy of FORD MOTOR CO.
Refer to: WHEEL AND TIRE .
New units must be configured using the Programmable Module Installation Routine in the diagnostic tool.
General Equipment : Ford Diagnostic Equipment
Upload the module information from the diagnostic tool to the module using the Programmable Modules Installation routine.
General Equipment : Ford Diagnostic Equipment