lock FORD FIESTA 2007 Workshop Manual

308-03125 Manual Transmission/Transaxle 308-03-25
REMOVAL
12. Disconnect the gearshift actuator electrical 1. Detach the gearshift cables and the selector
connector (colored grey). cable from the selector levers.
2. Turn the abutment sleeve clockwise and
detach the cables from the bracket.
13. ACAUTION:~~ brake fluid is spilt on the
paintwork, the affected area must be
All vehicles immediately washed down with cold water. 16. Remove the accessory drive belt cover.
Disconnect the clutch slave cylinder supply
line.
Remove the spring clip.
Vehicles without automated gearshift
14. Remove the gearshift cables cover.
I*' A~AuT10N:~rotect the ball joint seal
using a soft cloth to prevent damage.
Detach the lower arm from the wheel knuckle
15. Detach the gearshift cables from the on both
sides.
transaxle.
2006.0 Fiesta 1212006 GI 13290en
procarmanuals.com

308-03-26 Manual Transmission/Transaxle 308-03-26
REMOVAL
Remove the heat shield. 3. Remove the center bearing cap.
19. CAUTIONS: 21. CAUTIONS:
Asupport the halfshaft. The inner joint A~upport the halfshaft. The inner joint
must not be bent more than
18 degrees.
must not be bent more than 18 degrees.
The outer joint must not be bent more than
The outer joint must not be bent more than
45 degrees. 45 degrees.
ADO not damage the halfshaft oil seal. ADO not damage the halfshaft oil seal.
N0TE:Plug the transaxle to prevent oil loss or dirt N0TE:PIug the transaxle to prevent oil loss or dirt
ingress. ingress.
Using the special tool, detach the left-hand
Detach the halfshaft and the intermediate
halfshaft from the transaxle and secure
it to
shaft from the transaxle and secure it to one
one side. side.
Discard the snap ring. Allow the oil to drain into a suitable container.
Allow the oil to drain into a suitable container.
22. Lower the vehicle.
20. N0TE:Discard the intermediate shaft center
bearing cap and locknuts.
Remove the intermediate shaft center
bearing cap.
1. Remove the locknuts.
2. Detach the heat shield.
-- -
2006.0 Fiesta 1212006 GI I 3290en
procarmanuals.com

308-03-32 Manual Transmission/'rransaxle 308-03-32
REMOVAL
2. Turn the abutment sleeve clockwise and
detach the cables from the bracket. 17' ACAUTION:~~~~ bending of the exhaust
flexible pipe may cause damage resulting
/
in failure. \.
Support the exhaust flexible pipe with a
suitable support wrap or suitable splint.
13. Remove the accessory drive belt cover.
14. Remove the engine support insulator.
15. Remove the left-hand halfshaft.
For additional information, refer to: Front
Halfshaft LH
(205-04 Front Drive
Halfshafts, Removal and Installation).
16. Remove the right-hand halfshaft.
For additional information, refer to: Front
Halfshaft RH
(205-04 Front Drive
Halfshafts, Removal and Installation).
18. Lower the vehicle.
Igm ACAUTION:~~ brake fluid is spilt on the
paintwork, the affected area must be
immediately washed down with cold water.
Disconnect the clutch slave cylinder supply
line.
Remove the spring clip.
20.
Detach the exhaust flexible pipe from the
catalytic converter.
2006.0 Fiesta 1212006 G453416en
procarmanuals.com

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
procarmanuals.com

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
procarmanuals.com

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
procarmanuals.com

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
procarmanuals.com

308-03-50 Manual Transmission/Transaxle 308-03-50
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Selector Plate(l6 284 8)
Overview, selector mechanism
1 2 1 Selector plate I
Item Description 5. Fifth and reverse gear selector shaft guide
1 4 1 Selector shaft interlock mechanism I
1
1 5 1 Selector shaft I
Fifth and reverse gear selector shaft guide
1 6- 1 Reverse gear selector lever return sleeve.
sleeve
1 7 1 Reverse gear selector lever I
Disassembly
1. Remove the selector mechanism.
8
9
1. Fifth and reverse gear selector shaft.
2. Selector shaft.
3. Reverse gear selector lever .
Snap-ring
Fifth and reverse gear selector shaft
4. Selector plate.
Assembly
1, Install the selector mechanism.
1 . Selector shaft.
2. Reverse gear selector lever.
3. Fifth and reverse gear selector shaft guide
sleeve.
-- - - - -- --
2006.0 Fiesta 1212006 G18lllen
procarmanuals.com

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
procarmanuals.com

308-03-54 Manual Transmission/Transaxle 308-0344
ASSEMBLY
3. Move the third and fourth gear shift forks to
the installation position.
8. N0TE:lnstall a rubber band to the second
selector shaft to aid assembly.
2. lnstall the snap ring.
10. N0TE:lnstall a new snap ring.
lnstall the selector shaft guide sleeve upper
snap ring.
- lnstall the input shaft, the output shaft and
the selector forks. 1. Lift the guide sleeve.
2. lnstall the snap rina.
Insert the input shaft to a depth of I
approximately 50 mm and move it slightly to
one side.
Insert the output shaft to the level of the input
shaft and engage the gear wheels.
lnstall the input shaft and the output shaft.
9. N0TE:lnstall a new snap ring.
lnstall the selector shaft guide sleeve lower
snap ring.
1. lnstall the guide sleeve.
11. Move the inner gearshift linkage to the fifth
gear.
Before pressing it downwards, turn the
selector shaft clockwise until it reaches the
reverse and fifth gear passage.
12. lnstall the 3.8 mm thick measuring shim
and secure
it with a punch mark.
2006.0 Fiesta 1212006 G23119en
procarmanuals.com