2007 FORD FIESTA transmission

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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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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