Gearbox with drive axle (1.8L diesel) — removal (Power unit / Mechanical gearbox MTX-75 / Ford Focus 1 1998-2004)

Special tool

	Ball joint puller 211-020 (13-006)
	Engine support beam 303-290A (21-140A)
	Adapter for 303-290A (21-140) 303-290-01 (21-140-01)
	Adapter for 303-290A (21-140) 303-290-02 (21-140-02)
	Adapter for 303-290A (21-140) 303-290-03A (21-140-03A)
	Adapter for 303-290A (21-140) 303-290-06 (21-140-06)
	Drive axle puller 308-192 (16-057)

General equipment:

Jack for gearbox
Technological plugs
Fixing clamp

Withdrawal

All cars

1. General notes:

Items for which actions apply to specific variants, and not to all vehicles, are marked with a special note.

2. Remove the battery. Refer to Section 414-01 for more information.

3. Remove the battery shelf.

1. Release and disconnect the plug connector.
2. Turn out bolts.
3. Release the wiring harness.

4. Loosen the suspension strut nuts five turns, on both sides.

5. Disconnect the intercooler duct.

6. Disconnect the plug connector of the air intake temperature sensor (IAT).

7. Disconnect the intercooler.

8. Remove the air filter housing.

1. Release the hose clamp.
2. Disconnect the plug connector.
3. Disconnect the vacuum hose.

9. Remove the air intake pipe.

10. Disunite the plug connector and disconnect the wires of the glow plugs.

1. Alternator connector
2. High pressure fuel pump connector
3. Wire glow plug

11. Disconnect the oil separator of the crankcase ventilation system.

12. Release the wiring harness and unplug the engine cooling fan connector.

13. Disconnect the power steering high pressure pipe bracket.

14. Disconnect plug connectors.

Vehicle speed sensor (VSS)
transmission wiring harness
Reversing light switch

15. Remove the fan.

Release the clips on both sides and pull the fan down and out.

16. Disconnect the catalytic converter from the exhaust manifold (four nuts).

17. Raise the vehicle. Refer to Section 100-02 for more information.

18. Disconnect the front left wheel.

19. Disconnect the drive belt cover.

Disconnect the engine protection (nine bolts) (in the presence of).

20. Disconnect the tie rod end nut from the left wheel steering knuckle.

21. Disconnect the tie rod joint from the left steering knuckle.

Press the tie rod end out of the steering knuckle using the special tool.

22.

CAUTION: Do not damage the case.

Disconnect both lower suspension arms and the left stabilizer link arm (left side shown).

Remove the heat shield.

23. Disconnect the starter and tie it up.

24. Disconnect the bearing cover of the intermediate shaft of the right axle shaft.

Discard nuts and bearing cap.

25.

CAUTION: The inner hinge must not be tilted more than 18 degrees and the outer hinge must not be tilted more than 45 degrees.

NOTE: Plug the hole in the gearbox using a service plug.

Remove the intermediate shaft with the axle shaft from the gearbox and tie them.

26.

CAUTION: The inner hinge must not be tilted more than 18 degrees and the outer hinge must not be tilted more than 45 degrees.

NOTE: Plug the hole in the gearbox using a service plug.

NOTE: Discard retaining ring as it is no longer needed.

Disconnect the left axle shaft from the gearbox.

Disconnect the axle shaft from the gearbox using the special tool.
Remove the axle shaft from the gearbox and tie it.

27. Remove the catalytic converter with flexible exhaust pipe. Refer to Section 309-00 for more information.

28. Remove the roll limiter.

Vehicles manufactured up to 10.2001

29. Disconnect the shift cables from the shift lever.

1. Disconnect the shift cable from the shift lever.
2. Disconnect the gear selection cable from the gear lever.

30. Disconnect the shift cables from the bracket.

1. Release the support bracket by turning it counterclockwise and disconnect the shift cable.
2. Release the support bracket by turning it counterclockwise and disconnect the gear selection cable.

Vehicles manufactured since 10.2001

31.

NOTE: Press the shift cable release buttons.

Disconnect the shift cables from the gearbox.

1. Disconnect the shift cable from the shift lever.
2. Disconnect the gear select cable from the select lever.

32. Disconnect the shift cables from the bracket.

1. Release the support bracket by turning it counterclockwise and disconnect the shift cable.
2. Release the support bracket by turning it counterclockwise and disconnect the gear selection cable.

All cars

33. Lower the car.

34.

WARNING: Brake fluid leakage. Avoid contact of brake fluid with skin and eyes. If brake fluid comes into contact with the skin or eyes, immediately flush the affected area with water.

CAUTION: If brake fluid comes into contact with the paintwork, immediately wash the affected area with water.

Disconnect the high pressure line from the clutch slave cylinder.

Remove the clamp.
Remove the high pressure line from the bracket and tie it down.

35. Disconnect the coolant line from the bracket.

Remove the transmission harness connector bracket.
Attach the coolant line.

36. Turn out the top bolts of a flange.

37. Connect special tools.

38. Disconnect the rear engine mount.

39. Slightly lower the engine/gearbox assembly using the special tool 303-290A.

40. Remove the rear engine mount bracket.

41. Raise the vehicle. Refer to Section 100-02 for more information.

42. Slide the engine/gearbox assembly forward and insert a piece of wood approximately 350 mm long between the engine and subframe.