Transmission

1. Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).
   

1. NOTICE: Make sure that the component aligns with the installation mark.

   NOTE: This step is only necessary when installing a new component.

1. NOTICE: Make sure that the retaining strap is not trapped.

   NOTICE: Take extra care not to damage the wiring harnesses.

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

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

   NOTE: Make sure that the component is installed to the position noted before removal.

1. Tighten on both sides simultaneously.
   Torque : 48 Nm

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

1. Torque :
   1   90 Nm
   2   125 Nm

1. Special Tool(s) : 303-F072 Support Bar, Engine

1. NOTICE: Make sure that new nuts are installed.

   NOTICE: Only rotate the crankshaft clockwise.

   General Equipment : Magnetic Socket
   Torque :
     Stage 1:  5 Nm
     Stage 2:  25 Nm

1. Refer to: Starter Motor (303-06A Starting System - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, Removal and Installation).
   

1. Torque : 48 Nm

1. Torque : 25 Nm

1. Torque : 70 Nm

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

1. Torque : 48 Nm

1. Remove the General Equipment : Cable Ties

1. NOTE: If the transmission has been replaced or overhauled, the halfshaft 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) : 307-671 Installer, Axle Seal , 205-153 (T80T-4000-W) Handle

1. NOTE: Do not fully install halfshaft at this time.

   Using part: 97ZT-7M181-A.
   

1. NOTE: Insert halfshaft until circlip is fully seated. When checking if circlip is seated do not pull on CV joints or damage can result.

1. Torque : 52 Nm

1. Torque : 26 Nm

1. NOTE: If the transmission has been replaced or overhauled, the halfshaft 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) : 307-671 Installer, Axle Seal , 205-153 (T80T-4000-W) Handle

1. NOTE: Do not fully install intermediate 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. WARNING: Make sure that the wiring harnesses are correctly located.

   NOTICE: Take extra care not to damage the wiring harnesses.

1. Torque : 25 Nm

1. Torque : 48 Nm

1. Torque : 10 Nm

1. Refer to: Selector Lever Cable Adjustment (307-05 Automatic Transmission External Controls - Vehicles With: 6-Speed PowerShift Transmission - DPS6/6DCT250, General Procedures).
   

1. 2. Torque : 8 Nm

1. 1. Torque : 25 Nm
   2. Torque : 10 Nm

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

1. NOTE: New units must be configured using the Programmable Module Installation Routine in the diagnostic tool.

   Install all recovered module information after installing the transmission.
   Refer to: Transmission Control Module (TCM) Adaptive Learning (307-01 Automatic Transmission - Vehicles With: 6-Speed PowerShift Transmission - DPS6/6DCT250) .
   General Equipment : Ford Diagnostic Equipment

1. Refer to: Transmission Fluid Level Check (307-01 Automatic Transmission - Vehicles With: 6-Speed PowerShift Transmission - DPS6/6DCT250, General Procedures).
   

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