1990 FORD SIERRA change time

the crossmember to the gearbox, 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.
14Lower the gearbox slightly on the jack,
then remove the securing circlip, and
disconnect the speedometer drive cable from
the gearbox.
15Disconnect the wiring from the reversing
lamp switch. On models with fuel injection,
disconnect the wiring from the vehicle speed
sensor mounted in the side of the gearbox.
16Unscrew the two securing bolts, and
disconnect the gear linkage support bracket
from the gearbox.
17Using a suitable pin punch, drive out the
roll-pin securing the gearchange rod to the
gear linkage.
18Attach a suitable hoist to the engine lifting
brackets located at the front and rear of the
cylinder head, and carefully take the weight of
the engine. Arrange the lifting tackle so that
the engine/gearbox assembly will assume a
steep angle of approximately 40º to 45º as it is
being removed.
19To improve clearance in the engine
compartment when lifting the engine, unbolt
the engine mounting brackets from the
cylinder block, and remove them.
20Ensure that the steering wheel is
positioned in the straight-ahead position, then
remove the clamp bolt from the lower steering
column clamp, swivel the plate to one side,
and disconnect the lower steering column
from the lower flexible coupling.
21Detach the brake lines from the front
suspension crossmember.
22Support 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 sufficiently to allow
the engine sump to clear the steering rack and
crossmember as the engine/gearbox
assembly is removed.
23Make a final check to ensure that all
relevant wires, pipes and hoses have been
disconnected to facilitate removal of the en-
gine/gearbox assembly.
24Raise the engine/gearbox, at the same
time lowering the trolley jack which is
supporting the gearbox.
25Place a suitable rod across the vehicle
underbody to support the gear linkage
support bracket whilst the gearbox is
removed.
26Tilt 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.
27If the vehicle is to be moved while the
engine/gearbox assembly is removed,
temporarily refit the suspension crossmember
and the anti-roll bar to the underbody, and
reconnect the steering column to the
intermediate shaft.Separation
28To separate the engine from the gearbox,
proceed as follows.
29Remove the starter motor.
30Support the engine and gearbox
horizontally on blocks of wood.
31Unscrew 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.
32Unscrew the bolt from the engine adapter
plate.
33Pull 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.
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.
Removal
1Proceed as described in paragraphs 1 to 21
of Section 5.
2Unscrew the securing bolt, and disconnect
the earth lead from the rear left-hand side of
the cylinder head.
3Unscrew the nuts securing the engine
mountings to the engine mounting brackets.
4Jack 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.
5To improve access, disconnect the exhaust
downpipe from the manifold, and remove the
exhaust system.
6Drain the engine oil into a suitable
container.
7On 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.
8Remove the propeller shaft.
9Where 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.
10Support the transmission with a trolley
jack, using a block of wood between the jack
and the transmission to spread the load.
11Unscrew the four bolts securing thetransmission 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.
12Lower the transmission slightly on the
jack.
13Unscrew 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.
14Remove 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.
15Disconnect the wiring from the starter
inhibitor switch, kickdown solenoid, lock-up
clutch, reversing lamp switch, and where
applicable, the 3rd/4th gearchange solenoid.
16Remove the securing screw, and
disconnect the speedometer cable from the
transmission extension housing. Plug the
opening in the transmission to prevent dirt
ingress.
17Proceed as described in paragraphs 18 to
27 of Section 7, substituting transmission for
gearbox, and ignoring paragraph 25.
Separation
18To separate the engine from the
transmission, proceed as follows.
19Remove the starter motor.
20Support the engine and transmission
horizontally on blocks of wood.
21Working through the starter motor
aperture, unscrew the four torque converter-
to-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.
22Where applicable, remove the bolt
securing the transmission fluid dipstick tube
to the left-hand side of the cylinder block.
23Unscrew 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-to-
transmission bolts.
24Unscrew the bolt from the engine adapter
plate and, where applicable, pull the blanking
plug from the adapter plate.
25Pull 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.
8Engine/automatic
transmission assembly -
removal and separation
2B•6DOHC engine