2007 FORD FIESTA Workshop Manual

308-0347 Manual Transmission/Transaxle 308-03-47
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Using the special tool and a suitable press ,
/' install the ball bearing.
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2006.0 Fiesta 12/2006 G21537en
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308-0348 Manual TransmissionlTransaxle 308-03-48
General Equipment
1 press I
1 Drift I
Materials
Name
S~ecification
1 Transmission Oil I WSD-M2C200-C I
Disassembly
1. Using the special tools, remove the
differential taper roller bearings.
I. Install the special tool.
2. Remove the differential taper roller bearings.
1. Rotate the differential pinions approximately
90 degrees in the differential case and
remove them.
2. Remove and discard the snap ring and using
a suitable drift, drive out the pin.
Remove the two differential pinions and
plastic thrust elements.
3. Remove the ring gear retaining bolts.
2006.0 Fiesta 1212006 G21541 en
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308-0349 Manual Transmission/Transaxle 308-03-49
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Assembly 3. Using the special tool, install the differential
taper roller bearings.
I 1. N0TE:Do not lubricate the differential
bearings.
Carefully clean and check all components
and coat them with clean transmission oil
before assembly.
2. N0TE:lnstall a new differential pinion snap
ring.
lnstall the ring gear and the differential
pinions.
1. Using the old bolts, carefully attach the ring
gear to the differential case.
1 I
Discard the ring gear bolts.
2. lnstall the two differential pinions, plastic
thrust elements and using a suitable drift,
install the pin and snap ring.
3. lnstall the differential pinions and rotate them
90 degrees in the differential case.
3. N0TE:lnstall new ring gear retaining bolts.
N0TE:Do not rest the differential on the lower
differential taper roller bearing.
Using the special tool, install the differential
taper roller bearings and tighten the ring gear
retaining bolts.
1 . lnstall new ring gear retaining bolts and
tighten the bolts working diagonally.
2. lnstall the vehicle speed sensor (VSS) sensor
ring.
2006.0 Fiesta 1212006 G21541 en
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308-03-50 Manual Transmission/Transaxle 308-03-50
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Selector Plate(l6 284 8)
Overview, selector mechanism
1 2 1 Selector plate I
Item Description 5. Fifth and reverse gear selector shaft guide
1 4 1 Selector shaft interlock mechanism I
1
1 5 1 Selector shaft I
Fifth and reverse gear selector shaft guide
1 6- 1 Reverse gear selector lever return sleeve.
sleeve
1 7 1 Reverse gear selector lever I
Disassembly
1. Remove the selector mechanism.
8
9
1. Fifth and reverse gear selector shaft.
2. Selector shaft.
3. Reverse gear selector lever .
Snap-ring
Fifth and reverse gear selector shaft
4. Selector plate.
Assembly
1, Install the selector mechanism.
1 . Selector shaft.
2. Reverse gear selector lever.
3. Fifth and reverse gear selector shaft guide
sleeve.
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2006.0 Fiesta 1212006 G18lllen
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308-03-51 Manual Transmission/Transaxle 308-03-51
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
4. Selector plate.
2006.0 Fiesta 1212006 Gl8lllen
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308-03-52 Manual Transmission/Transaxle 308-03-52
ASSEMBLY
Transaxle(l6 11 8 8)
Special Tool(s)
Installer, Wheel Hub Bearing
Conelseal
205-296 (1 5-085)
15085
I I Adapter for 303-060 I
21 02402
Mounting Stand
303-435 (2 1 -1 87)
Adapter for
303-060
303-060-02 (2 1 -024-02)
I I Installer, Halfshaft Seal
Special Tool(s)
Installer, lnput Shaft Bearing
308-041 (1 6-020)
I I Installer, Extension Housing I
1 press I
16031
I Dial indicator gauge I
Installer, lnput Shaft Snap
Ring
308-076 (1 6-03 1
)
I Magnetic stand for dial indicator gauge
Seneral Equipment
I Blanking plugs I
I M8 x 50 mm bolt I
Thread die
Materials
Name Specification
1 Sealant I ESEE-M4G1008-A I
1 Transmission Oil I WSD-M2C200-C I
I Oil Pan Sealer I WSK-M2G348-A5 I
I Silicon Sealer I WSE-M4G323-A4 I
High Temperature
Grease
1. Clean and check all parts carefully before
reassembly.
Apply clean transmission oil to all running
surfaces.
2006.0 Fiesta 1212006 G23119en
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308-03-53 Manual Transmission/Transaxle 308-03-53
ASSEMBLY
*' ACAUTION:M~~~ sure the output shaft 2. lnstall the fifth and reverse gear selector
roller bearing is installed with the scribed shaft.
text uppermost.
Using the special tool, install the output shaft
roller bearing and the output shaft bearing
cup.
1. lnstall the oil funnel.
2. lnstall the output shaft roller bearing.
3. Using the special tool, install the differential
bearing cup.
4, lnstall the fifth and reverse gear selector
shaft, and the shift lock.
1, lnstall the shift lock.
5. lnstall the reverse gear idler.
6. lnstall the differential assembly and the
permanent magnet.
7. Prepare the input and output shaft for
installation.
1. Engage the input shaft and output shaft.
2. Move the first and second gear shift forks to
the installation position.
2006.0 Fiesta 1212006 G23119en
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308-03-54 Manual Transmission/Transaxle 308-0344
ASSEMBLY
3. Move the third and fourth gear shift forks to
the installation position.
8. N0TE:lnstall a rubber band to the second
selector shaft to aid assembly.
2. lnstall the snap ring.
10. N0TE:lnstall a new snap ring.
lnstall the selector shaft guide sleeve upper
snap ring.
- lnstall the input shaft, the output shaft and
the selector forks. 1. Lift the guide sleeve.
2. lnstall the snap rina.
Insert the input shaft to a depth of I
approximately 50 mm and move it slightly to
one side.
Insert the output shaft to the level of the input
shaft and engage the gear wheels.
lnstall the input shaft and the output shaft.
9. N0TE:lnstall a new snap ring.
lnstall the selector shaft guide sleeve lower
snap ring.
1. lnstall the guide sleeve.
11. Move the inner gearshift linkage to the fifth
gear.
Before pressing it downwards, turn the
selector shaft clockwise until it reaches the
reverse and fifth gear passage.
12. lnstall the 3.8 mm thick measuring shim
and secure
it with a punch mark.
2006.0 Fiesta 1212006 G23119en
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