2007 FORD FIESTA Workshop Manual

308-03-31 Manual TransmissionlTransaxle 308-03-31
REMOVAL
5. Remove the transaxle upper retaining bolts. Detach the wiring harness from the retaining
bracket.
6. Detach the power steering high-pressure line
retaining bracket from the transaxle. 10.
Disconnect the reversing lamp switch
electrical connector.
7. Remove the front wheels and tires.
11. Remove the gearshift cables cover.
For additional information, refer to: Wheel
and Tire (204-04 Wheels and Tires, Removal
I
and Installation).
8. Remove the wiring harness retaining bracket.
9. Remove the starter motor. 12.
Detach the gearshift cables from the
transaxle.
1. Detach the gearshift cables and the selector
cable from the selector levers.
- -
2006.0 Fiesta 1212006 G453416en
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308-03-32 Manual Transmission/'rransaxle 308-03-32
REMOVAL
2. Turn the abutment sleeve clockwise and
detach the cables from the bracket. 17' ACAUTION:~~~~ bending of the exhaust
flexible pipe may cause damage resulting
/
in failure. \.
Support the exhaust flexible pipe with a
suitable support wrap or suitable splint.
13. Remove the accessory drive belt cover.
14. Remove the engine support insulator.
15. Remove the left-hand halfshaft.
For additional information, refer to: Front
Halfshaft LH
(205-04 Front Drive
Halfshafts, Removal and Installation).
16. Remove the right-hand halfshaft.
For additional information, refer to: Front
Halfshaft RH
(205-04 Front Drive
Halfshafts, Removal and Installation).
18. Lower the vehicle.
Igm ACAUTION:~~ brake fluid is spilt on the
paintwork, the affected area must be
immediately washed down with cold water.
Disconnect the clutch slave cylinder supply
line.
Remove the spring clip.
20.
Detach the exhaust flexible pipe from the
catalytic converter.
2006.0 Fiesta 1212006 G453416en
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308-03-33 Manual Transmission/Transaxle 308-03-33
REMOVAL
Discard the gasket.
,
23. Using the special tools, lower the engine
and transaxle assembly.
21. Remove the battery tray support bracket.
24. Remove the engine and transaxle rear
mount retaining bracket.
22. Remove the engine and transaxle rear
mount.
Discard the nuts. 25. Raise and support the vehicle. For
additional information, refer to:
(1 00-02
Jacking and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
26. Remove the transaxle lower retaining bolts.
27. N0TE:Secure the transaxle with a retaining
strap on the transmission jack.
2006.0 Fiesta 1212006 G453416en
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308-03-34 Manual Transmission/Transaxle 308-03-34
REMOVAL
Using a suitable transmission jack, support
the transaxle. 30. Using a suitable transmission jack, remove
the transaxle.
//
28. Remove the transaxle right-hand retaining
bolts.
29. Remove the transaxle left-hand retaining
bolt.
2006.0 Fiesta luzoo6 G453416en
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308-03-35 Manual Transmission/Transaxle 308-03-35
DISASSEMBLY
Transaxle(l6 11 8 8)
- Special Tool(s)
I Remover, Drive Pinion Seal I
15074
I I Separator, Oil Pan
Remover,
Differential Bearing
Cone
205-1 76 (1 5-074)
i
Mounting Stand
303-435 (21 -1 87)
Mounting Bracket,
EngineIDifferential
205-329 (1 5-1 05A)
Special Tool(s)
I I Installer, Extension Housing I
I I Remover, Input Shaft Fifth I
General Equipment
I Blanking plugs
1 Drift I
CAUTIONS:
Use vise protectors.
A Use a copper or plastic mallet to prevent
damage.
1. Using the special tools, mount the transaxle
on the mounting stand.
2. Clean any grease and foreign material from
the input shaft.
2006.0 Fiesta 1212006 G23118en
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308-03-36 Manual Transmission/Transaxle 308-03-36
DISASSEMBLY
3. Remove the clutch slave cylinder. 2. Remove and discard the snap ring.
J'
4. Remove the vehicle speed sensor (VSS) (if 7m Remove the gearshift cable
equipped).
1. Remove the retaining pin.
2. Pull out the VSS.
5. Remove the selector mechanism cover.
6. Remove the gearshift lever.
1 . Remove the protective cap (if equipped).
8. Remove the selector lever.
Remove the bellows.
2006.0 Fiesta 1212006 G23118en
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308-03-37 Manual Transmission/Transaxle 308-03-37
DISASSEMBLY
9. Remove the selector interlock mechanism. 2. Remove and discard the retaining pin.
10. Remove the fifth gear housing cover 13. N0TE:To aid assembly mark the position
retaining bolts. of
the fifth gear synchroniser assembly.
11. Using the special tool, remove the fifth gear
housing cover.
12. Remove the fifth gear synchroniser
assembly, the selector fork and the fifth
gear.
I. Remove and discard the snap ring. I
Disassemble the fifth gear and synchroniser
assembly.
1. Snap ring.
2. Retaining plate.
3. Synchroniser assembly.
4. Synchroniser ring.
5. Fifth gear.
14. Remove the fifth gear snap ring.
2006.0 Fiesta 1212006 G23118en
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308-03-38 Manual Transmission/Transaxle 308-03-38
DISASSEMBLY
Discard the snap ring. 4. Pull out the blanking plug.
15. Using the special tool, remove the fifth
18. Using the special tool, remove both
gear. halfshaft oil seals (left-hand side shown).
16. Remove the fifth gear housing.
Discard the bolts.'
17. Remove the fifth gear housing gasket, the
snap rings and the blanking plug.
1. Remove and discard the gasket.
2. Remove the output shaft snap ring.
3. Remove the input shaft snap ring.
Only remove the reversing lamp switch if
there is evidence of leakage.
19. Separate the two halves of the transaxle
housing (14 bolts).
Carefully separate the transaxle housing.
20. Remove the selector shaft guide sleeve
upper snap ring.
I' j '\.
1. Remove and discard the upper snap ring.
2006.0 Fiesta 1212006 G23118en
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