Ford Fiesta Quiz
Manual Transmission, Clutch, Transfer Case and Power Transfer Unit

Transmission. Installation

In this manual: Manual Transmission, Clutch, Transfer Case and Power Transfer Unit
Service Information — 27Suspension — 48Transmission — 9Brake System — 52Steering — 21Engine — 140Manual Transmission, Clutch, Transfer Case and Power Transfer Unit — 48Exhaust System — 6Fuel System — 21Climate Control System — 58Instrumentation and Warning Systems — 26Battery and Charging System — 20Infotainment Systems — 41Lighting — 29Power Distribution — 11Electronic Function Group — 30Body and Paint — 275Frame and Mounting — 3
41steps
~256min
5/5difficulty
2special tools
0204060801004835N·mlb·ft
Tightening torque found on this page
Done 0 of 41

Special Service Tools / General Equipment

205-115A (205-115)
Installer, Pinion Seal
Transmission Jack
Retaining Strap
Wood block

Materials

Name Specification
Motorcraft® 4x4 High-Temperature Front Axle and Hub Bearing Grease
XG-11		 WSS-M1C267-A1
  1. Apply a thin layer of grease to the input shaft.
    Material: Motorcraft® 4x4 Front Axle and Hub Bearing High Temperature Grease / XG-11 (WSS-M1C267-A1)
  2. Install the following components:
    • Use common equipment: wooden block
    • Use common equipment: transmission jack.
    • Use common equipment: Retaining Strap
  3. Install the transaxle onto the locating dowels and install the case bolts.
    Torque: 35 lb-ft (48 N·m)
  4. Remove the following components:

    • Use common shop equipment: Retaining strap

    • Use common shop equipment: Transmission jack.

    • Use common shop equipment: Wood block
  5. Install the transmission mount bracket and bolts.
    Torque: 59 lb-ft (80 N·m)
    1. Install the transmission mount bracket bolts.
      Torque: 66 lb-ft (90 N·m)
    1. Install the transmission mount bracket nuts.
      Torque: 92 lb-ft (125 N·m)
  7. Connect the hydraulic tube to the slave cylinder.
  8. Install the hood panel.
    Refer to: Hood Panel (501-02 Front End Body Panels, Removal and Installation).
  9. Install the lower shield bolts.
    Torque: 35 lb-ft (48 N·m)
  10. Remove and discard the left halfshaft seal.
  11. Using the special tool, install a new left halfshaft seal.
    Use the special service tool: 205-115A (205-115) Installer, Pinion Seal.
  12. Install the halfshaft retaining ring.
    • Use new part: AA5P-4N206-A.
      Pull the LH axle shaft outward to make sure the retaining clip is locked.
    • Remove the special tool before fully installing the axle shaft.
  14. Remove the seal protector and fully insert the left halfshaft until the retaining ring seats.
  15. Install the LH brake hose to the strut.
    Torque: 19 lb-ft (26 N·m)
  16. Remove and discard the RH axle shaft seal.
  17. Using the special tool, install a new right halfshaft seal.
    Use the special service tool: 205-115A (205-115) Installer, Pinion Seal.
    • Use new part: AA5P-4N206-A.
    • Remove the special tool before fully installing the axle shaft.
  19. Install the right half shaft.
  20. Tighten:
    Install new axle shaft bearing strap and nuts.
    Torque:
    Stage 1: Lower nut: 44 lb-in (5 N·m)
    Stage 2: Upper nut: 18 lb-ft (25 N·m)
    Stage 3: Lower nut: 18 lb-ft (25 N·m)
  21. Install the RH brake hose to the strut.
    Torque: 19 lb-ft (26 N·m)
  22. Install the front subframe.
    Refer to: Front Subframe (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
  23. Install the bolts and roll restrictor.
    Torque: 52 lb-ft (70 N·m)
  24. Install the catalytic converter support bracket.
    Torque: 18 lb-ft (24 N·m)
  25. Install the muffler and exhaust pipe flange nuts and gasket.
    Torque: 35 lb-ft (48 N·m)
  26. Install the rear exhaust pipe suspension insulator.
  27. Remove the flex pipe support.

  28. Install the CAC inlet tube assembly.
    1. Install the clamps.
      Torque: 44 lb-in (5 N·m)
    1. Install the nuts.
      Torque: 97 lb-in (11 N·m)

  29. Install the CAC outlet tube assembly and connect the electrical connector.
    1. Install the nut.
      Torque: 97 lb-in (11 N·m)
    1. Tighten the clamp.
      Torque: 44 lb-in (5 N·m)
  30. Check the transmission fluid level.
    Refer to: Transmission Fluid Level Check (308-03B Manual Transmission - 6-Speed Manual Transmission - B6, General Procedures).
  31. Install the starter motor.
  32. If equipped.
    Install the ground cable bracket, bolts and retainers.
    Torque: 35 lb-ft (48 N·m)
  33. Install the clutch housing bolts.
    Torque: 35 lb-ft (48 N·m)
  34. Install the shift cable bracket and bolts.
    Torque: 18 lb-ft (25 N·m)

  35. Install the shift cables.
    • Connect the electrical connector.
    • Slide the retainer and install the shifter cables onto the transaxle.
  36. Adjust the shift cable.
    Refer to: Shift Cable Adjustment - 6-Speed Manual Transmission - B6 (308-06 Manual Transmission External Controls - 5-Speed Manual Transmission Transaxle - B5/IB5/6-Speed Manual Transmission - B6, General Procedures).
  37. Install the battery tray bracket and nuts.
    Torque: 89 lb-in (10 N·m)
  38. Install the wiring harness.
    Torque: 89 lb-in (10 N·m)
  39. Install the battery tray.
    Refer to: Battery Compartment - 1.6 L EcoBoost (132 kW/180 L hp) - Sigma (414-01 Battery, Mounting and Cables, Removal and Installation).
  40. Bleed the clutch system.
    Refer to: Clutch System Bleeding (308-02 Clutch Controls - 5-Speed Manual Transmission; Manual Transmission - B5/IB5/6-Speed Manual Transmission - B6, General Procedures).
  41. If equipped.
    Install the engine outer shield.

Test yourself

A quick Ford Fiesta quiz: every answer comes with an explanation and a link to the manual page.