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2B•6 DOHC engine
7 Engine/manual gearbox
assembly - removal and
separation
Note: Refer to Part A, Section 4 of this Chapter
and to the warning that appears at the start of
Section 5 before proceeding. A hoist and lifting
tackle will be required for this operation.
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"). 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 mounting clamps
to the vehicle underbody. Lower the anti-roll
bar as far as possible.
10 Proceed as described in paragraphs 30
and 31 of Section 5.
11 Support the gearbox with a trolley jack,
using a block of wood between the jack and
the gearbox to spread the load.
12 Unscrew the four nuts securing the
gearbox
crossmember
underbody. Unscrew the central bolt securing
the crossmember to the gearbox, and remove
the crossmember. Note the position of the
earth strap, where applicable. Recover the
mounting cup, and the exhaust mounting
bracket and heat shield (as applicable).
13 Lower the gearbox slightly on the jack,
then remove the circlip, and disconnect the
speedometer drive cable from the gearbox.
14 Disconnect the wiring from the reversing
lamp switch, and on models with fuel-injection,
disconnect the wiring from the vehicle speed
sensor mounted in the side of the gearbox.
15 Slacken and remove the two bolts and
washers (one either side) securing the gear
linkage support bracket to the gearbox.
16 Using a pin punch, drive out the roll pin
securing the gearchange rod to the gear linkage.
17 Attach a hoist to the engine lifting brackets
located at the front and rear of the cylinder head,
and slowly take the weight of the engine. Arrange
the lifting tackle so that the engine/gearbox
assembly will assume a steep angle of
approximately 40° to 45° as it is being removed.
18 To improve clearance in the engine
compartment when lifting the engine, unbolt
the engine mounting brackets from the
cylinder block, and remove them.
19 Ensure that the steering wheel is positioned
in the straight-ahead position then, using a dab
of paint or a marker pen, make alignment marks
between the intermediate shaft lower clamp
and steering gear pinion. Slacken and remove
the lower clamp bolt then disconnect the
intermediate shaft from the steering gear.
20 Detach the brake lines from the front
suspension crossmember.
21 Support the crossmember with a jack (do not
remove the jack from under the gearbox), then
loosen the bolts securing the crossmember to the
underbody. Remove the crossmember securing
bolts, and carefully lower the crossmember to
allow sufficient room for the engine sump to clear
the steering rack and crossmember as the
engine/gearbox assembly is removed.
22 Make a final check to ensure that all
relevant wires, pipes and hoses have been
disconnected to facilitate removal of the
engine/gearbox assembly.
23 Raise the engine/gearbox, at the same
time lowering the trolley jack which is
supporting the gearbox.
24 Place a suitable rod across the vehicle
underbody to support the gear linkage support
bracket whilst the gearbox is removed.
25 Tilt the engine/gearbox assembly using
the hoist and the trolley jack, until the
assembly can be lifted from the vehicle. Take
care not to damage surrounding components.
26 If the vehicle is to be moved, with the
engine/gearbox assembly removed, temporarily
refit the suspension crossmember and the anti-
roll bar to the underbody, and reconnect the
steering column to the intermediate shaft.
27 To separate the engine from the gearbox,
proceed as follows.
28 Remove the starter motor.
to
the
vehicle
29 Support
horizontally on blocks of wood.
30 Unscrew the engine-to-gearbox 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 gearbox when
removing the lower engine-to-gearbox bolts.
31 Unscrew the bolt from the engine adapter
plate.
32 Pull the engine and gearbox apart, taking
care not to strain the gearbox input shaft. It
may be necessary to rock the units slightly to
separate them.
8 Engine/automatic
transmission assembly -
removal and separation
Note: Refer to Part A, Section 4 of this
Chapter and to the warning that appears at the
start 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
the
engine
and
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"). 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 mounting 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 the exhaust mounting
bracket and heat shield (as applicable).
12 Lower the transmission slightly on the jack.
13 Unscrew the unions and disconnect the
fluid cooler pipes from the transmission. Plug
gearbox
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 the selector
lever on the transmission.
15 Disconnect the wiring from the starter
inhibitor switch, downshift solenoid, lock-up
clutch, reversing lamp switch, and where
applicable, the 3rd/4th gearchange solenoid.
16 Remove
the
disconnect the speedometer cable (where
fitted) from the transmission extension
housing. Plug the opening in the transmission
to prevent dirt ingress.
17 Proceed as described in paragraphs 17 to 26
of Section 7, substituting transmission for
gearbox and ignoring paragraph 24.
18 To
separate
transmission, proceed as follows.
19 Remove the starter motor.
20 Support the engine and transmission
horizontally on blocks of wood.
securing
screw,
and
the
engine
from
the
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