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Section 3 (Automatic Transmission - DPS6/DCT250): Removal: Transmission

WARNING: This page is about a different variant/trim than selected.
SPECIAL TOOL/GENERAL EQUIPMENT DESCRIPTION

G09551453
 100-001  (T50T-100-A)
Slide Hammer
G09551454
 205-241  (T86P-3514-A)
Remover, Halfshaft
TKIT-2009TC-F
T86P-1000-S
TKIT-1986-F
G09551455
 205-290  (T89P-3415-B)
Remover, Halfshaft (Plate)
TKIT-1989-FLM
TKIT-1989-LM
G09551456
 303-F072 
Support Bar, Engine
Magnetic Socket
Transmission Jack
Retaining Strap
Wooden Block
  1. With the vehicle in NEUTRAL, position it on a hoist.

    Refer to: JACKING AND LIFTING - OVERVIEW .

  2. NOTE: TCM  Programming does not need to be performed if the transmission is being removed for flexplate or rear main seal service.

    Recover all module information before removing the transmission.

    Refer to: TRANSMISSION CONTROL MODULE (TCM) ADAPTIVE LEARNING  .

    General Equipment  : Ford approved diagnostic tool

  3. Remove the battery tray.

    Refer to: BATTERY TRAY - 1.6L DURATEC-16V TI-VCT (88KW/120PS) - SIGMA .

  4. Remove the air cleaner.

    Refer to: AIR CLEANER .

    1. Disconnect the retainers from the battery tray support bracket and position aside the wiring harness.
    2. Remove the nut and position aside the ground cable.
    3. Remove the nuts and remove the battery tray support bracket.
      G09551457
    1. Remove the wiring bracket bolt.
    2. Slide the bracket back and position the wiring bracket aside.
      G09551458
  7. Disconnect the selector lever cable end from the manual control lever.
    G09551459
  8. Remove the bolts and position aside the selector lever cable and bracket.
    G09551460
  9. NOTE: Make sure that all openings are sealed or debris can enter the transmission.

    Remove the vent tube from the transmission.

    G09551461
  10. Remove the wiring retainers from the bellhousing bolts.
    G09551462
  11. Remove the top bellhousing bolts.
    G09551463
  12. Remove the bolt and remove the ground strap from the transmission.
    G09551464
  13. NOTE: Take extra care not to damage the wiring harnesses.

    Unlock the TCM  electrical connector.

    G09551465
  14. NOTE: Make sure that the terminals or pins/sockets of the TCM  and the TCM  electrical connector are not bent or damaged.

    Disconnect the TCM  electrical connector.

    G09551466
  15. Remove the bolts and the splash shield.
    G09551467
  16. Remove and discard the oil filter.
    G09551468
  17. Remove the bolt and remove the oil cooler from the engine.
    G09551469
  18. Remove the starter motor.

    Refer to: STARTER MOTOR .

  19. Disconnect the CKP  sensor electrical connector.
    G09551470
  20. Remove the starter insulator.
    G09551471
  21. NOTE: Rotate the engine in a clockwise direction only or engine damage may occur.
    NOTE: Note the position of the components before removal.

    Remove the clutch-to-flexplate nuts.

    Use the General Equipment: Magnetic Socket

    G09551472
  22. Remove the bolts and the roll-restrictor. Disconnect the wiring retainer.
    G09551473
  23. Remove the bolt and disconnect the ground cable.
    G09551474
  24. If transmission disassembly or installation of a new transmission is necessary, drain the transmission fluid.

    Torque  : 32 lb.ft (43 Nm)

    G09551475
  25. Remove the front wheels.

    Refer to: WHEEL AND TIRE .

  26. Remove the bolt and remove the RH  brake hose from the strut.
    G09551476
  27. NOTE: Do not use a prying device or separator fork between the ball joint and the wheel knuckle. Damage to the ball joint or ball joint seal may result. Only use the pry bar by inserting it into the lower arm body opening.
    NOTE: Use care when releasing the lower arm and wheel knuckle into the resting position or damage to the ball joint seal may result.

    Remove and discard the RH  lower control arm nut and bolt.

    G09551477
  28. Remove and discard the intermediate shaft bearing cap and bearing cap nuts.
    G09551478
  29. NOTE: Do not pull on the halfshaft or the CV  joint will separate. Always pull on the intermediate shaft.

    Remove the intermediate shaft from the transmission and position it aside.

    G09551479
  30. Remove the bolt and remove the LH  brake hose from the strut.
    G09551480
  31. NOTE: Do not use a prying device or separator fork between the ball joint and the wheel knuckle. Damage to the ball joint or ball joint seal may result. Only use the pry bar by inserting it into the lower arm body opening.
    NOTE: Use care when releasing the lower arm and wheel knuckle into the resting position or damage to the ball joint seal may result.

    Remove and discard the LH  lower control arm nut and bolt.

    G09551481
  32. NOTE: Do not pull on the outer part of the halfshaft or the CV  joint will separate. Always pull on the inner part of the halfshaft.

    Using the special tools, release circlip from the transmission.

    Use Special Service Tool: 100-001 (T50T-100-A) Slide Hammer  , 205-290 (T89P-3415-B) Remover, Halfshaft (Plate)  , 205-241 (T86P-3514-A) Remover, Halfshaft  .

    G09551482
  33. Remove the half shaft from the transmission and position it aside.
    G09551483
  34. Remove the cowl panel.

    Refer to: COWL PANEL .

  35. Install the special tool and support the engine.

    Use Special Service Tool: 303-F072 Support Bar, Engine  .

    G09551484
  36. Remove the transmission support insulator.
    G09551485
    • Using the special tool, lower the transmission.

      Use Special Service Tool: 303-F072 Support Bar, Engine  .

      Dimension  : 2 in (45 mm)

      G09551486
  38. Remove the bellhousing bolts.
    G09551487
  39. NOTE: Take extra care not to damage the wiring harnesses.

    Install the following items:

    • Support the transmission with a transmission jack.

      Use the General Equipment: Transmission Jack

      Use the General Equipment: Wooden Block

    • Fasten the transmission to the transmission jack with a retaining jack.

      Use the General Equipment: Retaining Strap

      G09551488
  40. Remove the bellhousing bolts.
    G09551489
  41. NOTE: Make sure that the locating dowels remain installed.
    NOTE: Make sure that no components catch.

    Remove the transmission from the vehicle. Inspect the separator plate for damage and discard if necessary.

    G09551490
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