Automatic Transmission: Removal & Installation Ford Focus I facelift

Transmission Fluid Cooler Tube Replacement

Refer to TRANSAXLE/TRANSMISSION COOLING article.

REMOVAL

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-278237) article.
2. Remove the transmission fluid pan. Remove the bolts. Using a suitable tool, separate the bead of sealer.
3. Clean the silicone from the transmission fluid pan and transaxle case surfaces thoroughly with metal surface cleaner.

INSTALLATION

1. Apply a bead 1.5 mm (0.06 in) thick of sealer to the transmission fluid pan.
2. Install the transaxle fluid pan. Tighten to 10 Nm (89 lb-in).
3. Lower the vehicle.
4. Fill the transaxle with clean automatic transmission fluid.

1. Remove the fluid pan. For additional information, refer to «Transmission Fluid Pan»(ref-278257-S36101796162008012400000) .
2. Disconnect the transmission fluid temperature (TFT) sensor electrical connector.
3. Remove the fluid filter.
4. Remove the ground wire bolt. Disconnect the electrical connectors and remove the main control wiring harness. Solenoid SSC; Color N (Neutral/White). Solenoid SSE; Color G (Green). Solenoid SSD; Color L (Blue). Solenoid PCA; Color B (Black). Solenoid SSA; Color N (Neutral). Solenoid SSB; Color B (Black).
5. Remove the main control valve body and accumulators.
6. Remove the accumulator pistons and springs.

1. Install the accumulator pistons and springs. Accumulator 1 and 2. Accumulator N and D.
2. Install the main control valve body.
3. Tighten the main control valve body retaining bolts. Tighten the bolts in the sequence shown. Tighten to 9 Nm (80 lb-in).
4. Install the main control valve wiring harness, connect the electrical connectors and install the ground wire bolt. Solenoid SSC; Color N (Neutral/White). Solenoid SSE; Color G (Green). Solenoid SSD; Color L (Blue). Solenoid PCA; Color B (Black). Solenoid SSA; Color N (Neutral). Solenoid SSB; Color B (Black). Tighten to 10 Nm (89 lb-in).
5. Install the fluid filter.
6. Connect the TFT sensor electrical connector.
7. Install the fluid pan. For additional information, refer to «Transmission Fluid Pan»(ref-278257-S36101796162008012400000) .

1. Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-278287) article.
2. Remove the air cleaner assembly. Disconnect the crankcase ventilation hose. Disconnect the air cleaner outlet hose. Remove the bolts and pull out the air cleaner resonator.
3. Remove the air cleaner intake hose with the resonator.
4. Disconnect the turbine shaft speed (TSS) sensor electrical connector.
5. Remove the TSS sensor bolt and sensor. Check the TSS sensor bore.
6. Inspect the O-ring seal for nicks or cuts; install a new O-ring if necessary.

1. Apply a light coat of clean automatic transmission fluid to the O-ring seal before installation.
2. Install the TSS sensor and bolt. Tighten to 10 Nm (89 lb-in).
3. Connect the TSS sensor electrical connector.
4. Instal the air cleaner intake hose with the resonator.
5. Install the air cleaner assembly. Connect the crankcase ventilation hose. Connect the air cleaner outlet hose. Position the air cleaner into the resonator and install the bolts.
6. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-278287) article.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-278237) article.
2. Place a drain pan beneath the output shaft speed (OSS) sensor.
3. Remove the OSS sensor. Disconnect the electrical connector. Remove the bolt. Inspect the OSS bore.
4. Inspect the O-ring seal for nicks or cuts; install a new O-ring if necessary.

1. Install the OSS sensor. Tighten to 10 Nm (89 lb-in). Connect the electrical connector.
2. Lower vehicle.
3. Check the transmission fluid level and add automatic transmission fluid as necessary.
4. Start the engine and move the transaxle range selector lever through all gear positions.

1. Loosen the strut and spring assembly top mount nuts by 5 turns.
2. Loosen the tie-rod end retaining nut.
3. Using the special tool, detach the tie-rod from the wheel knuckle. Remove and discard the retaining nut.
4. Detach the lower arm from the wheel knuckle.
5. Using the special tools, detach the halfshaft from the transaxle. Allow the oil to drain into a suitable container.
6. Remove the halfshaft seal.

1. Using the special tools, install the halfshaft seal.
2. Attach the halfshaft to the transaxle.
3. Attach the lower arm to the wheel knuckle. Tighten to 63 Nm (46 lb-ft).
4. Attach the tie-rod end to the wheel knuckle. Tighten to 40 Nm (30 lb-ft).
5. Tighten the strut and spring assembly top mount nuts. Tighten to 35 Nm (26 lb-ft).
6. Check the transmission fluid level and top off with automatic transmission fluid, if necessary.

1. Loosen the strut and spring assembly top mount nuts by 5 turns.
2. Detach the lower arm from the wheel knuckle.
3. Remove and discard the center bearing cap and locknuts.
4. Detach the halfshaft from the transaxle and secure it to one side. Allow the oil to drain into a suitable container.
5. Remove the halfshaft seal.

1. Using the special tools, install the halfshaft seal.
2. Install the halfshaft into the transaxle.
3. Install the center bearing cap and locknuts. Tighten to 25 Nm (18 lb-ft).
4. Attach the lower arm to the wheel knuckle (LH side shown). Tighten to 63 Nm (46 lb-ft).
5. Tighten the strut and spring assembly top mount nuts. Tighten to 35 Nm (26 lb-ft).
6. Check the transmission fluid level and top off with automatic transmission fluid, if necessary.

1. Disconnect the transmission range (TR) sensor electrical connector and the selector lever cable.
2. Remove the TR sensor (automatic transaxle shown removed for clarity). Remove the manual control lever. Remove the bolts.

1. Install the TR sensor (automatic transaxle shown removed for clarity).
2. Using the special tool, align the TR sensor and tighten the bolts. Tighten to 10 Nm (89 lb-in).
3. Install the manual control lever. Tighten to 30 Nm (22 lb-ft).
4. Adjust the manual control lever to TR sensor D position. "1" Low 1 "2" Low 2 "D" Drive "N" Neutral "R" Reverse "P" Park When in position D the marks on the manual control lever line up with the marks on the TR sensor.
5. Connect the selector lever cable and the TR sensor electrical connector.

1. Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-278287) article.
2. Remove the air cleaner resonator. Disconnect the crankcase ventilation hose. Disconnect the air cleaner outlet hose. Remove the bolts and pull out the air cleaner resonator.
3. Loosen the LH strut and spring assembly top mount nuts by 5 turns.
4. Disconnect the electrical connectors. Transmission range (TR) sensor electrical connector. Transaxle solenoid electrical connector.
5. Disconnect the turbine shaft speed (TSS) sensor electrical connector.
6. Remove the nut from the electrical connector bracket.
7. Remove the nut and position the electrical connector bracket aside.
8. Remove the upper center converter housing bolts.
9. Using the special tool, secure the engine.
10. Remove the fluid filler tube and shift cable bracket bolts.
11. Remove the nut and bracket from the starter stud.
12. Remove the starter nuts, then disconnect the wiring from the starter.
13. Remove the 3 starter bolts and starter.
14. Remove the starter isolator.
15. Remove the engine RH support insulator. Remove the insulator bolt and nut. Remove the insulator bolt.
16. Disconnect the LH stabilizer bar at the strut.
17. Remove the LH tie-rod end nut.
18. Remove the RH tie-rod end nut.
19. Using the special tool, disconnect both of the tie-rods from the knuckles.
20. Disconnect both of the lower control arms from the knuckles.
21. Remove the mounting bracket nuts, then remove the bracket from the RH halfshaft intermediate bearing.
22. Remove the RH halfshaft. Position it aside and support the halfshaft with mechanic's wire.
23. Using the special tools, remove the LH halfshaft from the transaxle. Allow the oil to drain into a suitable container.
24. Disconnect the output shaft speed (OSS) sensor electrical connector.
25. Unbolt the shift cable clip.
26. Disconnect the transmission fluid cooler lines from the transaxle. Slide the connector fitting into the cooler line. Press the yellow release button. Pull the connector fitting from the cooler line.
27. Disconnect the shift cable from the manual control lever.
28. Rotate the crankshaft to gain access to the converter nuts, then remove the 4 nuts.
29. Remove the engine rear mount nuts and remove the rear mount.
30. Using the engine support bar, lower the engine and transaxle assembly slightly.
31. Remove the engine rear mount bracket nuts and remove the bracket.
32. Remove the fluid filler tube. Remove the bolt at the base and pull out the tube and position it aside.
33. Secure the transaxle with a high-lift jack using a safety strap.
34. Remove the 3 converter housing bolts.
35. Remove the 5 converter housing bolts.
36. Separate the transaxle from the engine and lower the transaxle.
37. If replacement of the transaxle is required, remove the differential opening cover.
38. Install the special tool, to prevent damage to the torque converter.

1. Make sure that the torque converter is installed correctly.
2. Check the installation depth of the torque converter. Lay a steel straightedge on the automatic transaxle flange. Check the installation depth between the transaxle flange and the torque converter centering spigot for the correct clearance.
3. Remove the special tool.
4. If the transaxle was replaced, install the transaxle opening cover.
5. Using a high-lift jack, secure the transaxle using a safety strap.
6. Move the transaxle into position.
7. Note the location of the different length bolts and install the 5 converter housing bolts. Tighten to 47 Nm (35 lb-ft).
8. Install the 3 converter housing bolts. Tighten to 47 Nm (35 lb-ft).
9. Install 4 new torque converter-to-flexplate nuts. Tighten to 40 Nm (30 lb-ft).
10. Remove the safety strap from the transaxle.
11. Install the fluid filler tube. Tighten to 8 Nm (71 lb-in).
12. Install the engine rear mount bracket. Tighten to 80 Nm (59 lb-ft).
13. Install the engine rear mount and nuts. Tighten to 48 Nm (35 lb-ft). Tighten to 150 Nm (111 lb-ft).
14. Install the fluid cooler tubes.
15. Connect the output shaft speed (OSS) sensor electrical connector.
16. Install the LH drive halfshaft.
17. Install the RH halfshaft together with the intermediate shaft.
18. Install the mounting bracket for the halfshaft intermediate bearing. Tighten to 25 Nm (18 lb-ft).
19. Install both of the lower control arms to the knuckles. Tighten to 63 Nm (46 lb-ft).
20. Install both of the tie-rod ends to the knuckles. Tighten to 40 Nm (30 lb-ft).
21. Connect the stabilizer bar at the strut. Tighten to 55 Nm (41 lb-ft).
22. Install the front wheels and tires. For additional information, refer to «WHEELS AND TIRES»(ref-278246) article.
23. Install the engine RH support insulator. Install the insulator bolt and nut. Tighten to 48 Nm (35 lb-ft). Install the bolt. Tighten to 48 Nm (35 lb-ft).
24. Install the starter isolator.
25. Install the starter motor and insert the 3 bolts. Tighten to 35 Nm (26 lb-ft).
26. Connect the oil sending unit.
27. Connect the starter motor electrical connectors.
28. Connect the bracket to the starter stud.
29. Install the fluid filler tube and shift cable bracket bolts. Tighten to 20 Nm (15 lb-ft). Tighten to 8 Nm (71 lb-in).
30. Note the location of the different length bolts and install the upper center converter housing bolts. Tighten to 47 Nm (35 lb-ft).
31. Position the electrical connector bracket and install the nut. Tighten to 25 Nm (18 lb-ft).
32. Install the electrical connector bracket nut. Tighten to 25 Nm (18 lb-ft).
33. Install the shift cable clip. Tighten to 47 Nm (35 lb-ft).
34. Connect the turbine shaft speed (TSS) sensor electrical connector.
35. Connect the shift cable to the manual control lever.
36. Connect the electrical connectors. Transmission range (TR) sensor. Transaxle solenoid electrical connector.
37. Tighten the LH strut and spring assembly top mount nuts. Tighten to 30 Nm (22 lb-ft).
38. Install the air cleaner resonator. Install the resonator and nuts. Connect the air cleaner outlet hose. Connect the crankcase ventilation hose.
39. Install the battery tray and battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-278287) article.
40. Fill the transaxle with clean automatic transmission fluid.