Section 3 (Manual Transmission - 6-Speed Manual Transmission - B6): Installation: Transmission

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Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	205-115A (205-115) Installer, Drive Pinion Seal
Transmission Jack
Retaining Strap
Wooden Block

Materials 

1. Apply a thin coating of grease on the input shaft.

   Material: Motorcraft® High Temperature 4x4 Front Axle and Wheel Bearing Grease / XG-11 (WSS-M1C267-A1)

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2. Install the following items:
   • Use the General Equipment: Wooden Block
   • Use the General Equipment: Transmission Jack
   • Use the General Equipment: Retaining Strap

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3. Install the transmission on the dowel pins and install the bellhousing bolts.

   Torque: 35 lb.ft (48 Nm)

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4. Remove the following items:
   • Use the General Equipment: Retaining Strap
   • Use the General Equipment: Transmission Jack
   • Use the General Equipment: Wooden Block

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5. Install the transmission support insulator bracket and the bolts.

   Torque: 59 lb.ft (80 Nm)

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6. 1. Install the transmission support insulator bracket bolts.

      Torque: 66 lb.ft (90 Nm)

   2. Install the transmission support insulator bracket nuts.

      Torque: 92 lb.ft (125 Nm)

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7. Connect the slave cylinder hydraulic tube to the slave cylinder.

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8. Install the cowl panel. Refer to: Cowl Panel .
9. NOTE: Note the different lengths of the bolts.

   Install the lower bellhousing bolts.

   Torque: 35 lb.ft (48 Nm)

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10. NOTE: If the transmission has been replaced or overhauled, the seals do not need to be replaced.

    Remove and discard the LH halfshaft seal.

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11. Using the special tool, install a new LH halfshaft seal. Use Special Service Tool: 205-115A (205-115) Installer, Drive Pinion Seal.

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12. Install the halfshaft retaining circlip.

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13. NOTE: Do not fully install shaft at this time.
    • Using part: AA5P-4N206-A. Pull the LH halfshaft outward to make sure the circlip is locked.
    • Remove the special tool before completely installing the halfshaft.

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14. NOTE: Insert halfshaft until circlip is fully seated. When checking if circlip is seated do not pull on CV joints or damage can result.

    Remove the seal protector and fully insert the LH halfshaft until the circlip is seated.

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15. Install the LH brake hose on the strut.

    Torque: 19 lb.ft (26 Nm)

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16. NOTE: If the transmission has been replaced or overhauled, the seals do not need to be replaced.

    Remove and discard the RH halfshaft seal.

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17. Using the special tool install the new RH halfshaft seal. Use Special Service Tool: 205-115A (205-115) Installer, Drive Pinion Seal.

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18. NOTE: Do not fully install shaft at this time.
    • Using part: AA5P-4N206-A.
    • Remove the special tool before completely installing the halfshaft.

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19. NOTE: Insert the intermediate shaft into the transmission until the intermediate shaft bearing is centered in the concave groove of the intermediate shaft bearing bracket.

    Install the RH halfshaft.

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20. Tighten: Install the new half shaft bearing strap and nuts.

    Torque: Stage 1: Lower nut: 44 lb.in (5 Nm) Stage 2: Upper nut: 18 lb.ft (25 Nm) Stage 3: Lower nut: 18 lb.ft (25 Nm)

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21. Install the RH brake hose on the strut.

    Torque: 19 lb.ft (26 Nm)

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22. Install the subframe. Refer to: Front Subframe .
23. Install the bolts and the roll restrictor.

    Torque: 52 lb.ft (70 Nm)

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24. Install the catalytic converter support bracket.

    Torque: 18 lb.ft (24 Nm)

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25. Install the muffler and tailpipe flange nuts and gasket.

    Torque: 35 lb.ft (48 Nm)

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26. Install the rear exhaust hanger isolator.

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27. Remove the flexpipe support.

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28. Install the CAC inlet tube assembly.
    1. Install the clamps.

       Torque: 44 lb.in (5 Nm)

    2. Install the nuts.

       Torque: 97 lb.in (11 Nm)

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29. Install the CAC outlet tube assembly and connect the electrical connector.
    1. Install the nut.

       Torque: 97 lb.in (11 Nm)

    2. Tighten the clamp.

       Torque: 44 lb.in (5 Nm)

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30. Check the transmission fluid level. Refer to: Transmission Fluid Level Check .
31. Install the starter motor.

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32. If equipped. Install ground cable mounting, bolts and retainers.

    Torque: 35 lb.ft (48 Nm)

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33. Install the bellhousing bolts.

    Torque: 35 lb.ft (48 Nm)

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34. Install the shift cable bracket and the bolts.

    Torque: 18 lb.ft (25 Nm)

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35. Install the transmission shift cables.
    • Connect the electrical connector.
    • Slide the locking tab and install selector lever cables on the transmission.

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36. Adjust the gearshift cable. Refer to: Gearshift Cable Adjustment - 6-Speed Manual Transmission - B6 .
37. Install the battery tray bracket and nuts.

    Torque: 89 lb.in (10 Nm)

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38. Install the wiring harness.

    Torque: 89 lb.in (10 Nm)

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39. Install the battery tray. Refer to: Battery Tray - 1.6L EcoBoost (132kW/180PS) - Sigma .
40. Bleed the clutch system. Refer to: Clutch System Bleeding .
41. If equipped. Install the engine appearance cover.

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