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Bill
Bill, Technician
Category: UK Ford
Satisfied Customers: 3306
Experience:  City & Guilds
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How to change a clutch on ford fiesta diesel van

Customer Question

How to change a clutch on ford fiesta diesel van
Submitted: 4 years ago.
Category: UK Ford
Expert:  Bill replied 4 years ago.
Manual Transmission/Transaxle - Transaxle-1.8L DieselFiesta 1996 (08/1995-02/2002)
Print Print Report An Error Report An Error
Removal Special Tool(s)

Click to resize 16087

 

Extractor pin, drive halfshaft

308-237 (16-087)

Click to resize 16089

 

Extractor, drive halfshaft (left-hand side)

308-256 (16-089)

Click to resize 21140

 

Engine support bar

303-290 (21-140)

Click to resize(NNN) NNN-NNNN width=

 

Adapter for 21-140

303-290-01 (21-140-01)

Click to resize(NNN) NNN-NNNN width=

 

Adapter for 21-140

303-290-03 (21-140-03)

General Equipment 32 mm socket wrench Materials Name Specification Transmission fluid WSD-M2C200-C

Removal

All Vehicles
  1. General note.
    • The position descriptions for the engine mountings and the engine roll restrictor are given looking from the transmission towards the engine.
  1. Preparatory operations
    • Make a note of the radio keycode.
    • Make a note of the preset radio stations.
  1. Remove the battery. For additional information, refer to Section 414-01 Battery, Mounting and Cables.

Click to resize T2103043

 

 

  1. Remove the battery box.

Click to resize T2102057

 

 

  1. NOTE: Use an Allen key to stop the piston rod from turning.

    On each side loosen the suspension strut top nut five turns.

Click to resize T2103003

 

 

  1. Detach the air intake pipe.
    1. Detach it from the inlet manifold (clip).
    1. Release it from its clip.
    1. Pull it out of the air cleaner housing (push-fit).
    1. Disconnect it from the resonator hose (clip).

Click to resize T2103054

 

 

  1. Remove the resonator.

Click to resize T2103060

 

 

  1. warningWARNING: Brake fluid contains polyglycol ether and polyglycol. Prevent eye contact. Wash your hands thoroughly after working with brake fluid. If brake fluid gets into the eyes, flush the eyes with cold running water for 15 minutes. If the irritation persists, call a doctor. If brake fluid is swallowed, drink water and induce vomiting. Call a doctor immediately. Failure to observe these instructions can lead to personal injury.

    cautionCAUTION: If brake fluid contacts the paintwork, rinse the affected areas immediately with cold water.

    Detach the hydraulic pipe of the clutch operating system.
    • Pull out the securing clip and disconnect the pipe.
    • Seal the opening with a suitable plug.

Click to resize T2103062

 

 

  1. NOTE: The bracket of the catalyst is secured with a bolt.

    Remove the upper transmission flange bolts.

Click to resize T1601054

 

 

  1. Fit the special tools.
    • Slightly raise the engine and transmission assembly.

Click to resize T2103049

 

 

  1. Detach the rear engine mounting from the transmission.
    • Pull out the transmission breather.

Click to resize T2103045

 

 

  1. Remove the front engine mounting bracket.
  1. Raise the vehicle. For additional information, refer to Section 100-02 Jacking and Lifting.

Click to resize T2103030

 

 

  1. Disconnect the shift rod and the shift rod stabilizer.
    1. Shift rod
    1. Shift rod stabilizer

Click to resize T2103041

 

 

  1. NOTE: The engine roll restrictor is under tension.

    Remove the engine roll restrictor.

Click to resize T2103029

 

 

  1. Pull off the connector of the multi-function switch (or reversing light switch if necessary) (multi-function switch connector shown).

Click to resize T2103063

 

 

  1. Disconnect the speedometer drive cable from the transmission.

Click to resize T2103050

 

 

  1. Disconnect the starter motor.
    • Remove the four bolts.
    • Unclip the wiring loom.
    • Tie the starter motor up.

Click to resize C1402031

 

 

  1. Detach the lower suspension arm from the spindle carrier on each side (left-hand side shown).
Vehicles with a two-part intermediate shaft

Click to resize E0004817

 

 

  1. Detach the clamping strap.

Click to resize T1402008

 

 

  1. cautionCAUTION: The inner joint must not be bent at more than 18 degrees; the outer joint must not be bent at more than 45 degrees.

    Separate the left-hand front drive halfshaft together with tripode joint from the tripode housing, swing it backwards and tie it up.
    • Remove the grease from inside the joint.

Click to resize M1601036

 

 

  1. Undo the front drive halfshaft centre bearing.

Click to resize T1402016

 

 

  1. cautionCAUTION: The inner joint must not be bent at more than 18 degrees; the outer joint must not be bent at more than 45 degrees.

    NOTE: The intermediate shaft extension remains in the transmission.

    Detach the intermediate shaft from the intermediate shaft extension (shown with the intermediate shaft extension removed).
    1. Undo the clamping straps.
    1. Slide the boot onto the intermediate shaft.
Vehicles with a one-part intermediate shaft

Click to resize C1603024

 

 

  1. cautionCAUTION: The inner joint must not be bent at more than 18 degrees; the outer joint must not be bent at more than 45 degrees.

    Press the left-hand front drive halfshaft out of the transmission and suspend it towards the front.
    • Seal the transmission opening with auxiliary plugs.
  1. cautionCAUTION: The inner joint must not be bent at more than 18 degrees; the outer joint must not be bent at more than 45 degrees.

    Extract the right-hand front drive halfshaft from the transmission.

Click to resize T2102051

 

 

  1. cautionCAUTION: The inner joint must not be bent at more than 18 degrees; the outer joint must not be bent at more than 45 degrees.

    NOTE: Do not damage the boots of the drive halfshaft.

    Tie up the right-hand front drive halfshaft at the front.
All vehicles
  1. Lower the vehicle.

Click to resize T2103051

 

 

  1. Lower the transmission.
    • Lower the transmission just far enough with Special Tool 21-140 so that the studs of the engine mounting bracket are accessible.
  1. Raise the vehicle. For additional information, refer to Section 100-02 Jacking and Lifting.
    • Support the transmission on a transmission jack.

Click to resize T2103052

 

 

  1. Remove the resonator stud.

Click to resize T2103053

 

 

  1. Remove the six flange bolts.
    • Separate the transmission from the engine and lower it.
Bill, Technician
Category: UK Ford
Satisfied Customers: 3306
Experience: City & Guilds
Bill and 4 other UK Ford Specialists are ready to help you
Expert:  Bill replied 4 years ago.
Manual Transmission/Transaxle - Transaxle-1.8L DieselFiesta 1996 (08/1995-02/2002)
Print Print Report An Error Report An Error
Removal Special Tool(s)

Click to resize 16087

 

Extractor pin, drive halfshaft

308-237 (16-087)

Click to resize 16089

 

Extractor, drive halfshaft (left-hand side)

308-256 (16-089)

Click to resize 21140

 

Engine support bar

303-290 (21-140)

Click to resize(NNN) NNN-NNNN width=

 

Adapter for 21-140

303-290-01 (21-140-01)

Click to resize(NNN) NNN-NNNN width=

 

Adapter for 21-140

303-290-03 (21-140-03)

General Equipment 32 mm socket wrench Materials Name Specification Transmission fluid WSD-M2C200-C

Removal

All Vehicles
  1. General note.
    • The position descriptions for the engine mountings and the engine roll restrictor are given looking from the transmission towards the engine.
  1. Preparatory operations
    • Make a note of the radio keycode.
    • Make a note of the preset radio stations.
  1. Remove the battery. For additional information, refer to Section 414-01 Battery, Mounting and Cables.

Click to resize T2103043

 

 

  1. Remove the battery box.

Click to resize T2102057

 

 

  1. NOTE: Use an Allen key to stop the piston rod from turning.

    On each side loosen the suspension strut top nut five turns.

Click to resize T2103003

 

 

  1. Detach the air intake pipe.
    1. Detach it from the inlet manifold (clip).
    1. Release it from its clip.
    1. Pull it out of the air cleaner housing (push-fit).
    1. Disconnect it from the resonator hose (clip).

Click to resize T2103054

 

 

  1. Remove the resonator.

Click to resize T2103060

 

 

  1. warningWARNING: Brake fluid contains polyglycol ether and polyglycol. Prevent eye contact. Wash your hands thoroughly after working with brake fluid. If brake fluid gets into the eyes, flush the eyes with cold running water for 15 minutes. If the irritation persists, call a doctor. If brake fluid is swallowed, drink water and induce vomiting. Call a doctor immediately. Failure to observe these instructions can lead to personal injury.

    cautionCAUTION: If brake fluid contacts the paintwork, rinse the affected areas immediately with cold water.

    Detach the hydraulic pipe of the clutch operating system.
    • Pull out the securing clip and disconnect the pipe.
    • Seal the opening with a suitable plug.

Click to resize T2103062

 

 

  1. NOTE: The bracket of the catalyst is secured with a bolt.

    Remove the upper transmission flange bolts.

Click to resize T1601054

 

 

  1. Fit the special tools.
    • Slightly raise the engine and transmission assembly.

Click to resize T2103049

 

 

  1. Detach the rear engine mounting from the transmission.
    • Pull out the transmission breather.

Click to resize T2103045

 

 

  1. Remove the front engine mounting bracket.
  1. Raise the vehicle. For additional information, refer to Section 100-02 Jacking and Lifting.

Click to resize T2103030

 

 

  1. Disconnect the shift rod and the shift rod stabilizer.
    1. Shift rod
    1. Shift rod stabilizer

Click to resize T2103041

 

 

  1. NOTE: The engine roll restrictor is under tension.

    Remove the engine roll restrictor.

Click to resize T2103029

 

 

  1. Pull off the connector of the multi-function switch (or reversing light switch if necessary) (multi-function switch connector shown).

Click to resize T2103063

 

 

  1. Disconnect the speedometer drive cable from the transmission.

Click to resize T2103050

 

 

  1. Disconnect the starter motor.
    • Remove the four bolts.
    • Unclip the wiring loom.
    • Tie the starter motor up.

Click to resize C1402031

 

 

  1. Detach the lower suspension arm from the spindle carrier on each side (left-hand side shown).
Vehicles with a two-part intermediate shaft

Click to resize E0004817

 

 

  1. Detach the clamping strap.

Click to resize T1402008

 

 

  1. cautionCAUTION: The inner joint must not be bent at more than 18 degrees; the outer joint must not be bent at more than 45 degrees.

    Separate the left-hand front drive halfshaft together with tripode joint from the tripode housing, swing it backwards and tie it up.
    • Remove the grease from inside the joint.

Click to resize M1601036

 

 

  1. Undo the front drive halfshaft centre bearing.

Click to resize T1402016

 

 

  1. cautionCAUTION: The inner joint must not be bent at more than 18 degrees; the outer joint must not be bent at more than 45 degrees.

    NOTE: The intermediate shaft extension remains in the transmission.

    Detach the intermediate shaft from the intermediate shaft extension (shown with the intermediate shaft extension removed).
    1. Undo the clamping straps.
    1. Slide the boot onto the intermediate shaft.
Vehicles with a one-part intermediate shaft

Click to resize C1603024

 

 

  1. cautionCAUTION: The inner joint must not be bent at more than 18 degrees; the outer joint must not be bent at more than 45 degrees.

    Press the left-hand front drive halfshaft out of the transmission and suspend it towards the front.
    • Seal the transmission opening with auxiliary plugs.
  1. cautionCAUTION: The inner joint must not be bent at more than 18 degrees; the outer joint must not be bent at more than 45 degrees.

    Extract the right-hand front drive halfshaft from the transmission.

Click to resize T2102051

 

 

  1. cautionCAUTION: The inner joint must not be bent at more than 18 degrees; the outer joint must not be bent at more than 45 degrees.

    NOTE: Do not damage the boots of the drive halfshaft.

    Tie up the right-hand front drive halfshaft at the front.
All vehicles
  1. Lower the vehicle.

Click to resize T2103051

 

 

  1. Lower the transmission.
    • Lower the transmission just far enough with Special Tool 21-140 so that the studs of the engine mounting bracket are accessible.
  1. Raise the vehicle. For additional information, refer to Section 100-02 Jacking and Lifting.
    • Support the transmission on a transmission jack.

Click to resize T2103052

 

 

  1. Remove the resonator stud.

Click to resize T2103053

 

 

  1. Remove the six flange bolts.
    • Separate the transmission from the engine and lower it.
Customer: replied 4 years ago.

Thanks for your reply,but unfortunately the images do not appear to be loaded so I could not see them.

Is it possible to re-upload them

 

Thanks

 

Tony

Expert:  Bill replied 4 years ago.

Sorry, but images wont load for some reason.

 

You will just have to follow instructions.

 

Bill.

Customer: replied 4 years ago.

Unfortunately the text without the images does not help me very much,as that was the reason I came to you.

I would appreciate if you could you try to send me the images again.

 

Many thanks

 

Tony

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