Transmission - 2.0L Duratec-HE (125kW/170PS) - MI4

For information on Ford Color Coded Illustrations refer to OEM Color Coding .

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	205-153 (T80T-4000-W) Handle
Courtesy of FORD MOTOR COMPANY	303-1554 Engine Support Bar
Courtesy of FORD MOTOR COMPANY	307-671 Installer, Axle Seal TKIT-2010D-FLM TKIT-2010D-ROW
Magnetic Socket
Ford Diagnostic Equipment
Transmission Jack
Retaining Strap
Wooden Block

Materials 

1. NOTE: If using the existing clutch assembly, align the index marks on the flexplate and the clutch stud made during removal.

   If using a new clutch assembly, make sure the flexplate-to-clutch alignment marks are aligned.

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2. NOTE: Make sure that the retaining strap is not trapped.
   NOTE: Take extra care not to damage the wiring harnesses.

   Install the following items:

   • Install the transmission on the transmission jack. Use the General Equipment: Transmission Jack. Use the General Equipment: Wooden Block
   • Fasten the transmission with a retaining strap. Use the General Equipment: Retaining Strap

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3. 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.

   Install the transmission on the dowel pins.

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4. Install the clutch housing bolt.

   Torque: 35 lb.ft (48 Nm)

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5. Install the clutch housing bolt.

   Torque: 35 lb.ft (48 Nm)

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6. Using the special tool, raise the engine. Use Special Service Tool: 303-1554 Engine Support Bar.

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7. Install the clutch housing bolts.

   Torque: 35 lb.ft (48 Nm)

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8. Install the lower clutch housing bolts.

   Torque: 35 lb.ft (48 Nm)

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9. Lower the vehicle. Install the transmission support insulator bracket.

   Torque: 59 lb.ft (80 Nm)

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10. Install the selector lever cable bracket.

    Torque: 133 lb.in (15 Nm)

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11. Install the transmission support insulator bracket.

    Torque: 109 lb.ft (148 Nm)

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12. NOTE: Failure to rotate the engine 5 times before flexplate-to-clutch nuts are installed may result in misalignment and engine vibration.
    NOTE: Only rotate the crankshaft clockwise.

    Rotate the crankshaft 5 times.

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13. NOTE: Ensure the clutch studs move freely prior to flexplate-to-clutch nut installation. Failure to do so will cause the clutch and flexplate alignment points to bind and prevent the clutch from fully seating, causing a 1st order engine vibration.

    Check to make sure that the clutch moves freely from the flex plate.

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14. NOTE: Rotate the engine in a clockwise direction only or engine damage may occur.

    Identify the flexplate-to-clutch nuts position as follow:

    • For the existing clutch assembly nut number 1 is the one at the index mark made during removal.
    • For new clutch assembly nut number 1 is the one at flexplate-to-clutch alignment marks.
    • The other nuts are numbered in clockwise sequence.

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15. NOTE: Make sure that new flexplate-to-clutch nuts are installed.
    NOTE: Rotate the engine in a clockwise direction only or engine damage may occur.
    NOTE: Using a magnetic socket will help ease the installation of new flexplate-to-clutch nuts. If the flexplate-to-clutch nuts fall into the clutch housing, the transmission will have to be removed to retrieve them.

    Install nuts 1, 3 and 5. Use the General Equipment: Magnetic Socket

    Torque: 106 lb.in (12 Nm)

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16. NOTE: Make sure that new flexplate-to-clutch nuts are installed.
    NOTE: Rotate the engine in a clockwise direction only or engine damage may occur.
    NOTE: Using a magnetic socket will help ease the installation of new flexplate-to-clutch nuts. If the flexplate-to-clutch nuts fall into the clutch housing, the transmission will have to be removed to retrieve them.

    Install the remaining nuts and tighten all nuts in the following sequence: 2, 3, 4, 5, 6, 1. Use the General Equipment: Magnetic Socket

    Torque: 18 lb.ft (25 Nm)

    multimedia:A supplement to the article is available.

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17. NOTE: Failure to torque the flexplate-to-clutch nuts in the sequence described may result in a first order engine vibration. Misalignment can be resolved by removing and discarding all 6 flexplate-to-clutch nuts and repeating the previous 2 steps.
    multimedia:A supplement to the article is available.
18. Install the roll restrictor in the subframe.

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19. NOTE: Note the length of the 2 roll restrictor bolts and be sure not to install the longer bolt into the subframe. If the longer bolt is installed in the subframe it can contact the steering gear causing NVH concerns.
    1. Install the roll restrictor bracket and install the bolts.

       Torque: 59 lb.ft (80 Nm)

    2. Install the roll restrictor-to-roll restrictor bracket bolt.

       Torque: 59 lb.ft (80 Nm)

    3. Install the roll restrictor-to-subframe bolt.

       Torque: 92 lb.ft (125 Nm)

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20. Install the wiring retainer.

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21. Install the clutch housing bolt.

    Torque: 35 lb.ft (48 Nm)

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22. Install the ground strap on the clutch housing bolt.

    Torque: 18 lb.ft (25 Nm)

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23. Install the starter insulator.

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24. Install the starter.

    Torque: 26 lb.ft (35 Nm)

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25. Install the wiring bracket on the starter.

    Torque: 97 lb.in (11 Nm)

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26. 1. Install the starter solenoid terminal nut.

       Torque: 53 lb.in (6 Nm)

    2. Install the positive battery terminal nut.

       Torque: 106 lb.in (12 Nm)

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27. NOTE: Clean and inspect the mating surfaces.
    NOTE: Install a new gasket.

    Install the oil filter adapter.

    Torque: 18 lb.ft (25 Nm)

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28. Connect the oil pressure sensor.

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29. NOTE: Lubricate the oil filter gasket with clean engine oil.

    Install a new oil filter.

    Material: Motorcraft® SAE 5W-20 Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

    Torque: Stage 1: 71 lb.in (8 Nm) | Stage 2: 180°

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

    Remove and discard the LH halfshaft seal.

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31. NOTE: Make sure that the mating faces are clean and free of corrosion and debris.

    Inspect the halfshaft seal sealing surface for corrosion and debris. Make sure the surface is clean.

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32. Using the special tools, install a new halfshaft seal. Use Special Service Tool: 307-671 Installer, Axle Seal, 205-153 (T80T-4000-W) Handle.

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33. NOTE: Do not fully install the halfshaft at this time.

    Using a seal protector, install the splines of the LH halfshaft in the transmission. Remove the seal protector.

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34. NOTE: Insert shaft until circlip is fully seated. When checking if circlip is seated, apply pulling force to the tulip housing only. Do not pull on CV joints or damage can result.

    Install the LH halfshaft into the transmission until the circlip is fully seated.

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35. Install the ball joint retainer on both sides.

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36. Install the LH ball joint into the knuckle. Install a new bolt and nut.

    Torque: 61 lb.ft (83 Nm)

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37. Install the LH brake hose.

    Torque: 89 lb.in (10 Nm)

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38. If equipped, install the LH ride height sensor.

    Torque: 177 lb.in (20 Nm)

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

    Remove and discard the RH halfshaft seal.

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40. NOTE: Make sure that the mating faces are clean and free of corrosion and debris.

    Inspect the halfshaft seal sealing surface for corrosion and debris. Make sure the surface is clean.

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41. Using the special tools, install a new halfshaft seal. Use Special Service Tool: 307-671 Installer, Axle Seal, 205-153 (T80T-4000-W) Handle.

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42. NOTE: Do not fully install the halfshaft at this time.

    Using a seal protector, install the splines of the intermediate shaft in the transmission. Remove the seal protector.

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43. Install the intermediate shaft in the transmission until the intermediate shaft support bearing is installed in the bracket.

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44. Install a new intermediate shaft support bearing cap and install new 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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45. Install the RH ball joint in the knuckle.

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46. Install a new RH ball joint bolt and nut.

    Torque: 61 lb.ft (83 Nm)

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47. Install the RH brake hose.

    Torque: 89 lb.in (10 Nm)

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48. If equipped, install the RH ride height sensor.

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49. Check and top off the transmission fluid. Refer to: Transmission Fluid Level Check .
50. Install the front wheels. Refer to: Wheel and Tire .
51. Install the underbody shield.

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52. Install the air deflector.

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53. Install the upper clutch housing bolts.

    Torque: 35 lb.ft (48 Nm)

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54. WARNING: Make sure that the wiring harnesses are correctly located.
    NOTE: Take extra care not to damage the wiring harnesses.

    Connect the TCM electrical connector.

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55. Lock the TCM electrical connector.

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56. Install the selector lever cable bracket and the bolts.

    Torque: 26 lb.ft (35 Nm)

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57. Adjust the selector lever cable. Refer to: Selector Lever Cable Adjustment .
58. Install the vent tube in the retainer.

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59. Install the battery tray support bracket.

    Torque: 35 lb.ft (48 Nm)

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60. Install the battery tray. Refer to: Battery Tray .
61. Install the engine appearance cover.

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62. Inspect and adjust the engine oil level.

    Material: Motorcraft® SAE 5W-20 Full Synthetic Motor Oil / XO-5W20-QFS (WSS-M2C945-A)

63. If a new transmission, TCM or PCM was installed, configure the TCM using the Programmable Module Installation Routine in the scan tool. If a new transmission, TCM or PCM was not installed, upload all recovered module information using the scan tool. Refer to: Transmission Control Module (TCM) Adaptive Learning . Use the General Equipment: Ford Diagnostic Equipment
64. Perform clutch, shift drum, and TR sensor adaptive learning. Refer to: Transmission Control Module (TCM) Adaptive Learning .
65. After completing the repairs, perform the Misfire Monitor Neutral Profile Correction procedure. Use the General Equipment: Ford Diagnostic Equipment