Engine-6-Speed PowerShift Transmission

https://www.etis.ford.com/wsm/js/procedure.do?variantId=3050&proc...
Engine - 1.5L Duratec-16V Ti-VCT

(81kW/110PS) - Sigma - Engine—6-Speed
PowerShift Transmission - DPS6/6DCT250
Print
Removal
Special Tool(s) / General Equipment

204-609
Protection Cap, Ball Joint Gaiter
205-775
Protector, Halfshaft Seal
Cable Ties
Floor Crane
Hose Clamp Remover/Installer
Lifting Bracket
Lower Arm Down Force Lever
Magnetic Socket
Mounting Table Set
Retaining Strap
Wooden Block
1. Refer to: Health and Safety Precautions (100-00 General Information, Description and
Operation).
2. Refer to: Fuel System Pressure Release (310-00B Fuel System - General Information - 1.5L
Duratec-16V Ti-VCT (81kW/110PS) - Sigma, General Procedures).
3. Remove the following items:

1. Refer to: Air Cleaner (303-12B Intake Air Distribution and Filtering - 1.5L Duratec-16V
Ti-VCT (81kW/110PS) - Sigma, Removal and Installation).
2. Refer to: Powertrain Control Module (PCM) (303-14B Electronic Engine Controls - 1.5L
Duratec-16V Ti-VCT (81kW/110PS) - Sigma, Removal and Installation).
3. Refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation).
4.
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5.
6.
7.
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8.
9.
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10. Use the General Equipment: Hose Clamp Remover/Installer
11. Refer to: Quick Release Coupling (310-00B Fuel System - General Information - 1.5L
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12.
13.
14. Refer to: Cooling System Draining and Vacuum Filling (303-03B Engine Cooling - 1.5L
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15.
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18. Remove the following items:

Refer to: Generator - 1.5L Duratec-16V Ti-VCT (81kW/110PS) - Sigma/1.6L Duratec-16V
(81kW/110PS) (414-02 Generator and Regulator, Removal and Installation).
Refer to: Cooling Fan Motor and Shroud (303-03B Engine Cooling - 1.5L Duratec-16V
Ti-VCT (81kW/110PS) - Sigma, Removal and Installation).
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21.
22. Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
23.
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24.
25.
26. Install the General Equipment: Lower Arm Down Force Lever
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27. Install Suggested Tool: 204-609. Tool shown or a commercially available equivalent can be
used.
28. NOTE: Be prepared to collect escaping fluid.
29. Install Special Service Tool: 205-775.
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30. NOTICE:
Make sure that the strut is not moved more than necessary to prevent damage to
top mount.
The inner constant velocity (CV) joint must not be bent more than 18°.
The outer constant velocity (CV) joint must not be bent more than 45°.
31. Remove the General Equipment: Lower Arm Down Force Lever
32.
33. Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
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34. If equipped.
35.
36.
37. NOTICE: Make sure that the strut is not moved more than necessary to prevent
damage to top mount.
Use the General Equipment: Lower Arm Down Force Lever
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38. Install Special Service Tool: 204-609.
39.
40. NOTICE: Make sure that the strut is not moved more than necessary to prevent
damage to top mount.
NOTE: Be prepared to collect escaping fluid.
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41. NOTICE:
top mount.
Take extra care not to damage the seal.

Install Special Service Tool: 205-775.
42. NOTICE:
top mount.
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43.
Vehicles with air conditioning
44. NOTICE: Make sure that no strain is placed on the refrigerant lines.
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All vehicles
45.
46.
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47.
48.
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49. NOTICE: Make sure that the exhaust flexible pipe is not forcibly bent or twisted.
Use the General Equipment: Cable Ties
50.
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51. NOTICE:
Make sure that the exhaust flexible pipe is not forcibly bent or twisted.
Make sure that the catalytic converter is supported with suitable retaining straps.
52.
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53. WARNING: Make sure that the engine and transmission assembly is on wooden blocks
and secured with suitable retaining straps.
Use the General Equipments: Mounting Table Set, Wooden Block, Retaining Strap
54. NOTE: Note the position of the component before removal.
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55.
56. NOTICE: Make sure that no components catch.

Raise and support the vehicle.
57. Use the General Equipments: Floor Crane, Lifting Bracket
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58. Remove the General Equipments: Wooden Block, Mounting Table Set, Retaining Strap
59. NOTICE: Take extra care not to damage the wiring harnesses.
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60. NOTICE: Make sure that the terminals or pins/sockets of the transmission control
module (TCM) and the TCM electrical connector are not bent or damaged.
61.
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62. NOTE: The gasket is to be reused unless damaged.
63. NOTICE: Only rotate the crankshaft clockwise.

NOTE: Note the position of the components before removal.
Use the General Equipment: Magnetic Socket
64.
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65.
66.
NOTICE: Make sure that the locating dowels remain installed.
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67.
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Engine-6-Speed PowerShift Transmission

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Engine-6-Speed PowerShift Transmission

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https://www.etis.ford.com/wsm/js/procedure.do?variantId=3050&proc...

Engine - 1.5L Duratec-16V Ti-VCT

Special Tool(s) / General Equipment

3. Remove the following items:

10. Use the General Equipment: Hose Clamp Remover/Installer

16. Use the General Equipment: Hose Clamp Remover/Installer

17. Use the General Equipment: Hose Clamp Remover/Installer

18. Remove the following items:

19. Use the General Equipment: Hose Clamp Remover/Installer

20. Use the General Equipment: Hose Clamp Remover/Installer

28. NOTE: Be prepared to collect escaping fluid.

29. Install Special Service Tool: 205-775.

Use the General Equipment: Lower Arm Down Force Lever

38. Install Special Service Tool: 204-609.

Take extra care not to damage the seal.

Vehicles with air conditioning

54. NOTE: Note the position of the component before removal.

56. NOTICE: Make sure that no components catch.

57. Use the General Equipments: Floor Crane, Lifting Bracket

62. NOTE: The gasket is to be reused unless damaged.

63. NOTICE: Only rotate the crankshaft clockwise.

NOTICE: Make sure that the locating dowels remain installed.

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