2007 FORD FIESTA Workshop Manual

308-03-39 Manual Transmission/Transaxle 308-03-39
DISASSEMBLY
2. Slide the selector shaft guide sleeve 23. Using a suitable drift remove and discard
downwards. the input shaft oil seal. i
21. Remove the selector shaft guide sleeve. 24. Remove the differential assembly and the
1. Remove and discard the selector shaft guide permanent magnet.
sleeve lower snap ring.
2. Remove the selector shaft guide sleeve.
22.
N0TE:lnstall a rubber band to the second
selector shaft to aid disassembly.
Remove the input shaft, the output shaft and
the selector forks as an assembly. 25.
Remove the reverse gear idler.
26. Remove the selector shaft and the shift
lock.
1. Remove the shift lock.
2006.0 Fiesta 1212006 G23118en
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308-0340 Manual Transmission/Transaxle 308-03-40
DISASSEMBLY
2. Remove the fifth and reverse gear selector
shaft. 29. Using the special tool, remove the
differential bearing cup.
f
27. Remove the output shaft roller bearing.
30. N0TE:lnstall the special tool in the
Remove the rollers and the roller cage from transaxle
housing grooves.
the output shaft roller bearing.
1 Using the special tool, remove the differential I
28m &AUTION:O~I~ use the special tool as
shown, failure to do so may result in the
blanking plug being pressed out of the
housing.
Using the special tool, remove the output
shaft roller bearing outer race.
Remove the oil funnel. bearing
cup.
2006.0 Fiesta 12/2006 G23118en
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308-0341 Manual Transmission/Transaxle 308-03-41
DISASSEMBLY AND ASSEMBLY
OF SUBASSEMBLIES
Output Shaft
Special Tool(s)
I I Remover, Bearing (Main I
I I Installer, Extension Housing I
Bushing Oil Seal
308-045
(1 6-0 1 5)
General
Eaui~ment
I Two-leg puller I
4. Remove the fourth gear and the synchronizer
ring.
1. Remove the ball bearing and the fourth gear.
Press
2. Remove the
third and fourth gear
1. Remove and discard the small snap ring.
2. Install the output shaft snap ring
.
3. Using a suitable two-leg puller, remove the
ball bearing.
Discard the output shaft snap ring and the
ball bearing.
Materials
3. Third gear synchronizer assembly.
synchronizer assembly.
1. Outer
synchronizer ring.
2. Synchronizer cone.
2006.0 Fiesta 1212006 G21539en
Name Specification I. Remove and discard the snap ring.
2. Remove the gear synchronizer, third and
Transmission
Oil
fourth gear synchronizer assembly and the
Disassembly third gear as an assembly.
WSD-M2C200-C
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308-03-42 Manual Transmission/Transaxle 308-03-42
DISASSEMBLY AND ASSEMBLY
OF SUBASSEMBLIES
3. Third gear.
4. Remove the second gear synchronizer
assembly
I. Retaining ring.
2. Snap rings.
3. Second gear.
4. lnner synchronizer ring.
5. Synchronizer cone.
6. Outer synchronizer ring.
5. N0TE:Remove the synchronizer assembly
and the first gear as an assembly.
Remove the first and reverse gear, the gear
synchronizer and synchronizer assembly.
1. Remove and discard the snap ring.
2. Remove the first and second gear
synchronizer clutch and the reverse gear
. ( \.. 3. Outer synchronizer ring.
4. Synchronizer cone.
5. lnner synchronizer ring.
6. First gear.
6m ACAUTION:T~ aid assembly mark the
position of the selector ring in relation to the
synchronizer hub.
Disassemble the synchronizer clutch.
I. Selector ring.
2. Synchronizer spring.
3. Synchronizer lock.
--
2006.0 Fiesta 1212006 G21539en
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308-0343 Manual TransmissionlTransaxle 308-03-43
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
4. Synchronizer hub.
7. Using the special tools, remove the output
shaft bearing cone.
1. Remove and discard the output shaft bearing
cone snap ring.
2. Install the special tools underneath the
bearing cone.
Discard the output shaft bearing cone.
Assembly
I. Coat the synchronizer assembly with clean
transmission oil before assembly.
2. Carefully clean and check all running
surfaces and coat them with clean
transmission oil before assembly.
3. N0TE:lnstall a new output shaft bearing cone
snap ring.
N0TE:lnstall a new output shaft bearing cone.
Install the output shaft bearing cone.
Evenly heat the bearing cone to
approximately
80°C and install it onto the
output shaft.
Install the snap ring.
4. N0TE:Assemble the synchronizer clutch to
the marks.
Assemble the synchronizer clutch.
I. Synchronizer hub.
2. Selector ring.
3. Synchronizer lock.
4. Synchronizer spring.
5.
N0TE:Use a new first and reverse gear snap
ring.
Install the first and reverse gear, the gear
synchronizer and synchronizer assembly.
1. First gear.
2. Inner synchronizer ring.
2006.0 Fiesta 1212006 G21539en
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308-03-44 Manual Transmission/Transaxle 308-03-44
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
3. Synchronizer cone. 6. Retaining ring.
4. Outer synchronizer ring.
5. lnstall the first and second gear synchronizer
clutch and the reverse gear.
6. lnstall the snap ring.
6. N0TE:Assemble the synchronizer assembly
before installation on the output shaft.
lnstall the second gear synchronizer
assembly.
1. Outer synchronizer ring.
2. Synchronizer cone.
3. Inner synchronizer ring.
4. Second gear.
5. Snap rings.
7. Third gear synchronizer assembly.
1. Third gear.
2. Synchronizer cone.
3. Outer synchronizer ring.
8. N0TE:lnstall a new third and fourth gear
synchronizer assembly snap ring.
N0TE:lnstall the selector ring with the annular
groove facing downwards and the small hub collar
facing upwards.
Install the third and fourth gear synchronizer
assembly.
2006.0 Fiesta 1212006 G21539en
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30810345 Manual Transmission/Transaxle 308103145
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
1. Install the gear synchronizer, third and fourth Install the snap ring.
gear synchronizer assembly and the third
(' gear.
2. lnstall the snap ring.
9. N0TE:lnstall a new snap ring.
N0TE:lnstall a new ball bearing.
N0TE:lnstall the ball bearing with the annular
groove facing outwards.
Using the special tool and a suitable press,
install the fourth gear and the ball bearing.
1. lnstall the synchronizer ring and the fourth
( gear.
2. Using a suitable press , install the ball
bearing.
2006.0 Fiesta 1212006 G21539en
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308-0346 Manual Transmission/Transaxle 308-03-46
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Input Shaft
Special Tool(s)
I I Installer, Extension Housing I
BushingIOil Seal
308-045
(1 6-0 1 5)
General Equipment
Two-leg puller
1 press I
Discard the ball bearing.
Materials
Name
S~ecification 1 Assembly
I Transmission Oil I WSD-M2C200-C I
Disassembly
1. Using a suitable two-leg puller, remove the
ball bearing.
1. Install the input shaft snap ring.
2. Remove the ball bearing.
Discard the input shaft snap ring and the
ball bearing.
I. Coat all components with clean transmission
oil before assembly.
2. N0TE:lnstall a new ball bearing.
Using the special tool and a suitable press
,
install the ball bearing.
/-
'.
3. N0TE:lnstall a new ball bearing.
N0TE:The ball bearing groove must face outwards.
2. Using a suitable two-leg puller remove the
ball bearing.
2006.0 Fiesta 1212006 G21537en
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