2007 FORD FIESTA table

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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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.
--
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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308-03-56 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.
- -
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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