2007 FORD FIESTA Workshop Manual

308-03-55 Manual Transmission/Transaxle 308-03-55
ASSEMBLY
1. Transaxle housing.
,, . 2. Measuring shim.
i 3. Bearing cup.
13. N0TE:Make sure that the transaxle housing
mating surfaces are clean.
Assemble the transaxle housing.
Using a M8 x 50 mm bolt install the special
15. Prepare the differential for measuring.
Turn the differential assembly approximately
ten times to settle the bearings.
Position the dial indicator gauge and
magnetic stand and set the dial indicator
gauge to zero.
Pre-tension the dial indicator gauge by a
minimum of
1 mm.
tool.
16. N0TE:Carry out the measuring procedure Install the blanking plugs.
three times and calculate the average value.
Install the bolts.
Turn the transaxle 180 degrees. N0TE:The adjusting shims are available from 0.1
'1 I mm to 1.1 mm in steps of 0.1 mm.
Measure the differential end float.
1. Using the special tool, lift the differential
assembly.
2. Note the resulting measurement.
Example: 0.73 mm
+ 0.74 mm + 0.72 mm
divided by three
= 0.73 mm.
The value of the thickness of the shim
should be rounded down to the nearest
tenth of a millimeter below if the value ends
14. Install the special tools.
Remove the blanking plugs.
2006.0 Fiesta 1212006 G23119en
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308-03-56 Manual Transmission/Transaxle 308-03-56
ASSEMBLY
in 0.05 mm and below, and rounded up to Remove the dial indicator gauge, the
the nearest tenth of a millimeter if the value
magnetic stand and the special tools.
ends in 0.06 mm and above.
17. Calculate the required adjusting shim
thickness.
Thickness of adjusting shim = measuring
shim (3.80 mm)
+ average value (0.73 mm)
+ bearing pre-load (0.14 mm) - thickness of
the Belleville washers (4.42 mm)
Example: Adjusting shim = 3.80 mm + 0.73
mm
+ 0.14 mm - 4.42 mm = 0.25 mm.
The thickness of the adjusting shim becomes
0.2 mm (rounded down from 0.25 mm).
18. Separate the transaxle housing.
lnstall the blanking plugs.
Turn the transmission approximately 180
degrees.
19. Using the special tool, remove the
differential bearing cup and the measuring
shim.
*Om ACAUTION:T~~ Belleville washers must
be installed with the inner diameter of both
washers touching.
lnstall the measured adjusting shim.
I. lnstall the Belleville washers.
2. lnstall the measured adjusting shim.
3. lnstall the bearing cone.
Using a suitable center punch, secure the
bearing cone.
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2006.0 Fiesta 1212006 G23119en
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308-03-57 Manual Transmission/Transaxle 308-03-57 I I
ASSEMBLY
21. Apply sealer on the inside edge of the Install
the fifth gear housing gasket.
1. transaxle housing mating face.
22. Assemble the transaxle housing and tighten 26m ACAUTION:M~~~ sure the snap rings are
in the correct position. Failure to follow this
the bolts.
instruction may cause damage to the fifth
23. N0TE:lnstall new input and output shaft
snap rings. gear
housing.
Turn the snap rings to the position shown.
Raise the and shafts 'lightly 27. NOTE:lnstall new fifth gear housing
and install the snap rings.
retaining bolts.
' 24. Using a suitable thread die, clean all the Install
the fifth gear housing.
-I hole threads in the fifth gear housing.
25. N0TE:lnstall a new fifth gear housing 28. Remove the transaxle from the mounting
stand.
gasket.
2006.0 Fiesta 1212006 G23119en
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308-03-58 Manual Transmission/Transaxle 308-03-58
ASSEMBLY
29. N0TE:The transaxle housing must not Correct installation position for the selector
contact the press table. Support the input shaft interlock mechanism.
shaft splines.
Using the special tool and a suitable press,
install the fifth gear.
33. Install the selector shaft interlock
mechanism.
Apply sealant to the thread.
30. Mount the transaxle on the mounting stand.
31. N0TE:lnstall a new fifth gear snap ring.
Install the fifth gear snap ring.
1. Install the snap ring onto the special tool.
2. Install the special tool and push on the snap
ring.
34. N0TE:Align the gear synchronizer to the
marks.
Assemble the fifth gear synchronizer.
I. Fifth gear.
2. Synchronizer ring.
3. Synchronizer assembly.
32. Make sure that the selector shaft is in the 4. Retaining plate.
neutral position.
2006.0 Fiesta 1212006 G23119en
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308-03-59 Manual Transmission/Transaxle 308-03-59
ASSEMBLY
35. N0TE:lnstall a new fifth gear synchronizer
assembly snap ring.
1 , N0TE:Use a new selector fork retaining pin.
lnstall the fifth gear synchronizer assembly
and the selector fork.
lnstall the retaining pin.
lnstall the snap ring.
36. Apply sealer evenly to the inside edge of
the fifth gear housing mating face.
37. lnstall the fifth gear housing cover.
38. lnstall the selector lever.
lnstall the bellows.
39. Engage the fifth gear.
Turn the selector shaft clockwise as far as
possible and push the shaft in.
40. N0TE:lnstall new halfshaft oil seals.
Using the special tools, install both halfshaft
oil seals (left-hand side shown).
2006.0 Fiesta 1212006 G23119en
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308-03-60 Manual Transmission/Transaxle 308-03-60
ASSEMBLY
41. lnstall the gearshift cable bracket. 2. lnstall the retaining pin.
42. N0TE:lnstall a new snap ring. 45m &AUTION:U~~~~ suitable adhesive tape,
Install the gearshift lever. cover
the input shaft splines to prevent
damage to the input shaft oil seal.
1. lnstall the snap ring.
2. lnstall the protective cap (if equipped). Position
the input shaft oil seal.
TIE
43. lnstall the selector mechanism cover. 46m ~CAUTION:DO not apply grease on any
parts of the clutch slave cylinder.
lnstall the clutch slave cylinder.
44. lnstall the vehicle speed sensor (VSS) (if
equipped).
1. Push in the VSS.
Tighten the bolts evenly. In doing so, press
the input shaft oil seal into the transmission
housing.
2006.0 Fiesta 1212006 G23119en
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308-03-62 Manual Transmission/'rransaxle 308-03-62
INSTALLATION
Transaxle - 1.25L Duratec-I 6V (Sigma)/Im4L Duratec-1 6V
(Sigma)/l .6L Duratec-1 6V (Sigma)(l 6 1 14 0)
Special Tool(s)
Support Bar, Engine
303-290A (21
-1 40A)
Adapter for 303-290A 303-290-0
1 (2 1 -1 40-0 1 )
Adapter for 303-290A
303-290-02 (21
-1 40-02)
21 14002
I I I
General Equipment
Retaining strap
I Transmission jack I
Materials
Name Specification
Installation
Manual transmission
1 fluid
All vehicles
I. CAUTIONS:
WSD-M2C200-C
&se suitable retaining straps to secure
the transaxle on the transmission jack.
A~ake sure that the two locating dowels
are installed.
Using a suitable transmission jack, install
the transaxle.
2. Install the transaxle right-hand retaining
bolts.
3. Install the transaxle lower retaining bolts.
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2006.0 Fiesta 1212006 GI 13293en
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