Transmission - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma

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

1. NOTICE: Make sure that the locating dowels remain installed.

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

1. Perform this and the following operation simultaneously.
   Torque : 48 Nm

1. Torque : 48 Nm

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

1. Torque : 80 Nm

1. NOTICE: Be prepared to collect escaping fluid.

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

1. Torque : 48 Nm

1. Torque : 48 Nm

1. Torque :
   1   63 Nm
   2   70 Nm

1. Torque : 25 Nm

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

1. NOTICE: Make sure that the mating faces are clean and free of corrosion and foreign material.

1. Special Tool(s) : 308-848 Installer, Driveshaft Seal

1. Refer to: Front Halfshaft LH (205-04 Front Drive Halfshafts, Removal and Installation).
   

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

1. NOTICE: Make sure that the mating faces are clean and free of corrosion and foreign material.

1. Special Tool(s) : 308-848 Installer, Driveshaft Seal

1. NOTE: Do not fully install the shaft at this time.

   Using part: 97ZT-7M181-A.
   

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

1. Torque :
     Stage 1:  Tighten the lower nut to 5 Nm
     Stage 2:  Tighten the upper nut to 24 Nm
     Stage 3:  Tighten the lower nut to 24 Nm

1. Torque : 52 Nm

1. Torque : 26 Nm

1. Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
   

1. Refer to: Transmission Fluid Level Check (308-03A Manual Transmission - Vehicles With: 5-Speed Manual Transmission - B5/IB5, General Procedures).
   

1. 1. Material : High Temperature Nickel Anti-Seize Lubricant / XL-2

   2. NOTE: Make sure that a new component is installed.

   3. NOTE: Make sure that new components are installed.

      Torque : 48 Nm

1. NOTICE: Make sure that the exhaust flexible pipe is not forcibly bent.

   • Remove the General Equipment : Cable Ties

1. Torque : 25 Nm

1. Torque : 25 Nm

1. Torque : 48 Nm

1. Refer to: Gearshift Cable Adjustment - Vehicles With: 5-Speed Manual Transmission - B5/IB5 (308-06 Manual Transmission External Controls - Vehicles With: 5-Speed Manual Transmission - B5/IB5/6-Speed Manual Transmission - B6, General Procedures).
   

1. If equipped.
   

1. Torque : 25 Nm

1. Torque : 10 Nm

1. Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, Removal and Installation).
   

1. Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).
   

1. Refer to: Battery Tray - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma (414-01 Battery, Mounting and Cables, Removal and Installation).
   

1. Refer to: Clutch System Bleeding (308-02 Clutch Controls - Vehicles With: 5-Speed Manual Transmission - B5/IB5/6-Speed Manual Transmission - B6, General Procedures).
   

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