2007 FORD FIESTA transmission oil

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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308-03-38 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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308-0343 Manual TransmissionlTransaxle 308-03-43
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
4. Synchronizer hub.
7. Using the special tools, remove the output
shaft bearing cone.
1. Remove and discard the output shaft bearing
cone snap ring.
2. Install the special tools underneath the
bearing cone.
Discard the output shaft bearing cone.
Assembly
I. Coat the synchronizer assembly with clean
transmission oil before assembly.
2. Carefully clean and check all running
surfaces and coat them with clean
transmission oil before assembly.
3. N0TE:lnstall a new output shaft bearing cone
snap ring.
N0TE:lnstall a new output shaft bearing cone.
Install the output shaft bearing cone.
Evenly heat the bearing cone to
approximately
80°C and install it onto the
output shaft.
Install the snap ring.
4. N0TE:Assemble the synchronizer clutch to
the marks.
Assemble the synchronizer clutch.
I. Synchronizer hub.
2. Selector ring.
3. Synchronizer lock.
4. Synchronizer spring.
5.
N0TE:Use a new first and reverse gear snap
ring.
Install the first and reverse gear, the gear
synchronizer and synchronizer assembly.
1. First gear.
2. Inner synchronizer ring.
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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308-0348 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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