2007 FORD FIESTA differential

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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308-03-39 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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308-0348 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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308-03-53 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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308-03-55 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.
- -
2006.0 Fiesta 1212006 G23119en
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