Engine/automatic transmission assembly - removal and separation
Note: Refer to the warning at the beginning of Section 5 before proceeding. A suitable hoist and lifting tackle will be required for this operation. Any suspected faults in the automatic transmission should be referred to a Ford dealer or automatic transmission specialist before removal of unit, as the specialist fault diagnosis equipment is designed to operate with the transmission in the vehicle.
1 Proceed as described in paragraphs 1 to 21 of Section 5.
2 Unscrew the securing bolt, and disconnect the earth lead from the rear left-hand side of the cylinder head.
3 Unscrew the nuts securing the engine mountings to the engine mounting brackets.
4 Jack up the vehicle and support it securely on axle stands. (see “Jacking and Vehicle Support”).
Ensure that there is enough working room beneath the vehicle.
5 To improve access, disconnect the exhaust downpipe from the manifold, and remove the exhaust system.
6 Drain the engine oil into a suitable container.
7 On models fitted with a catalytic converter, release the securing clips and withdraw the exhaust heat shield from under the vehicle for access to the propeller shaft.
8 Remove the propeller shaft.
9 Where applicable, bend back the locktabs, then unscrew the two bolts in each case securing the two anti-roll bar U-clamps to the vehicle underbody. Lower the anti-roll bar as far as possible.
10 Support the transmission with a trolley jack, using a block of wood between the jack and the transmission to spread the load.
11 Unscrew the four bolts securing the transmission crossmember to the vehicle underbody. Unscrew the central bolt securing the crossmember to the transmission, and remove the crossmember. Note the position of the earth strap, where applicable. Recover the mounting cup, and where applicable, the exhaust mounting bracket and heat shield.
12 Lower the transmission slightly on the jack.
13 Unscrew the unions and disconnect the fluid cooler pipes from the transmission. Plug the open ends of the pipes and the transmission, to prevent dirt ingress and fluid leakage. Where applicable, detach the fluid cooler pipe bracket from the engine mounting bracket, and move it to one side.
14 Remove the two clips securing the selector rod, and detach the selector rod from the manual selector lever, and from the selector lever on the transmission.
15 Disconnect the wiring from the starter inhibitor switch, kickdown solenoid, lock-up clutch, reversing lamp switch, and where applicable, the 3rd/4th gearchange solenoid.
16 Remove the securing screw, and disconnect the speedometer cable from the transmission extension housing. Plug the opening in the transmission to prevent dirt ingress.
17 Proceed as described in paragraphs 18 to 27 of Section 7, substituting transmission for gearbox, and ignoring paragraph 25.
18 To separate the engine from the transmission, proceed as follows.
19 Remove the starter motor.
20 Support the engine and transmission horizontally on blocks of wood.
21 Working through the starter motor aperture, unscrew the four torque converterto- driveplate nuts. It will be necessary to turn the crankshaft using a suitable spanner on the crankshaft pulley bolt in order to gain access to each nut in turn through the aperture.
22 Where applicable, remove the bolt securing the transmission fluid dipstick tube to the left-hand side of the cylinder block.
23 Unscrew the engine-to-transmission bolts, noting the locations of the bolts, and the positions of the earth strap and any wiring clips attached to the bolts. Recover any shims fitted between the sump and the transmission when removing the lower engine-totransmission bolts.
24 Unscrew the bolt from the engine adapter plate and, where applicable, pull the blanking plug from the adapter plate.
25 Pull the engine and the transmission apart, ensuring that the torque converter is held firmly in place in the transmission housing, otherwise it could fall out, resulting in fluid spillage and possible damage. It may be necessary to rock the units slightly to separate them.
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