2. Install the gearbox unit. Tightening torque: 65 Nm
3. Install the transmission support bracket. Tightening torque: M12 80 Nm. M8 24 Nm
4. Secure the ground cable to the gearbox bracket. Tightening torque: 25 Nm
5. Install the turbocharger outlet pipe.
6. Install the front flywheel cover. Tightening torque: 60 Nm
7. Install the right half shaft. Tightening torque: Propeller shaft support 25 Nm
8. Install the left axle shaft.
9. Install the adjusting tool on the front subframe.
10. Install the front subframe. Tightening torque: Support bracket bolts 25 Nm. Subframe bolts: Step 1: 140 Nm. Step 2: 240°
CAUTION: Use only new subframe bolts.
NOTE: Install, but do not fully tighten, the front subframe mounting bolts.
11. Install the subframe crossmember. Tightening torque: Crossmember bolts 45 Nm. Subframe bolts: Step 1: 140 Nm, Step 2: 240°
CAUTION: Use only new bolts.
NOTE: Install, but do not fully tighten, the rear subframe mounting bolts.
12. Install the lower support cushion. Tightening torque: 110 Nm
13. Install the fuel line.
14. Connect the steering gear pressure lines. Tightening torque: 25 Nm
15. Install the power steering fluid tube into the clamp.
16. Secure the catalytic converter to the distribution pipe.
17. Connect the ball joints of the left and right steering rod ends. Tightening torque: 80 Nm
WARNING: Use new nuts.
18. Install the lower control arm ball joint. Tightening torque: 110 Nm
CAUTION: Install a new lower control arm ball joint nut.
CAUTION: Do not allow the ball joint to rotate.
19. Attach both front struts to the stabilizer bar. Tightening torque: 55 Nm
WARNING: Use new nuts.
CAUTION: Do not allow the ball joint to rotate.
20. Install both fender splash guard extension panels.
NOTE: The illustration shows the right side, the procedure is similar on the left side.
21. Install the front wheel and tire assemblies. Refer to procedure: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).
22. Install 2 transmission-to-body mounting bolts. Tightening torque: 175 Nm
23. Remove the support from under the engine.
24. Install the starter. Refer to procedure: Starter (303-06B Starting System - 2.2L Duratorq - Td4, Removal and Installation).
25. Install the gearbox selector box. Refer to the procedure: Gearshift lever (308-06 External manual transmission controls in the drive axle/ gearbox unit, Removal and installation).
26. Connect the hydraulic hose of the clutch slave cylinder and secure with a clamp.
27. Connect the electrical connectors of the 1st and reverse gear position switch.
28.
NOTE: The moment the latches lock into place, there should be a distinct click.
29. Connect the steering column to the steering gear. Tightening torque: 25 Nm
CAUTION: Install a new steering column flexible coupling bolt.
30. Fill the gearbox with transmission fluid. Refer to the procedure: Draining transmission fluid from the gearbox and pouring transmission fluid into the gearbox (308-03 Manual Transmission/ Transmission in a drive axle unit, General procedures).
31. Install the battery tray. Refer to the procedure: Battery Installation Tray (414-01 Battery, Battery Fastener and Cables, Removal and Installation).
32. Bleed the clutch system. Refer to procedure: Bleeding the Clutch System (308-00 Manual/Transaxle Transaxle and Clutch - General Information, General Procedures).
33. Fill the power steering system with fluid and bleed the system. Refer to the procedure: Bleeding the Power Steering System (211-00 Steering System - General Information, General Procedures).
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