clutch FORD FIESTA 2007 Workshop Manual

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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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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308-03-44 Manual Transmission/Transaxle 308-03-44
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
3. Synchronizer cone. 6. Retaining ring.
4. Outer synchronizer ring.
5. lnstall the first and second gear synchronizer
clutch and the reverse gear.
6. lnstall the snap ring.
6. N0TE:Assemble the synchronizer assembly
before installation on the output shaft.
lnstall the second gear synchronizer
assembly.
1. Outer synchronizer ring.
2. Synchronizer cone.
3. Inner synchronizer ring.
4. Second gear.
5. Snap rings.
7. Third gear synchronizer assembly.
1. Third gear.
2. Synchronizer cone.
3. Outer synchronizer ring.
8. N0TE:lnstall a new third and fourth gear
synchronizer assembly snap ring.
N0TE:lnstall the selector ring with the annular
groove facing downwards and the small hub collar
facing upwards.
Install the third and fourth gear synchronizer
assembly.
2006.0 Fiesta 1212006 G21539en
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308-03-60 Manual Transmission/Transaxle 308-03-60
ASSEMBLY
41. lnstall the gearshift cable bracket. 2. lnstall the retaining pin.
42. N0TE:lnstall a new snap ring. 45m &AUTION:U~~~~ suitable adhesive tape,
Install the gearshift lever. cover
the input shaft splines to prevent
damage to the input shaft oil seal.
1. lnstall the snap ring.
2. lnstall the protective cap (if equipped). Position
the input shaft oil seal.
TIE
43. lnstall the selector mechanism cover. 46m ~CAUTION:DO not apply grease on any
parts of the clutch slave cylinder.
lnstall the clutch slave cylinder.
44. lnstall the vehicle speed sensor (VSS) (if
equipped).
1. Push in the VSS.
Tighten the bolts evenly. In doing so, press
the input shaft oil seal into the transmission
housing.
2006.0 Fiesta 1212006 G23119en
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308-03-64 Manual Transmission/Transaxle 308-03-64
INSTALLATION
13. Connect the vehicle speed sensor (VSS) 16. Raise and support the vehicle. For
electrical connector (if equipped). additional information, refer to
Section 100-02 [Jacking and Lifting].
17. CAUTIONS:
Asupport the halfshaft. The inner joint
must not be bent more than 18 degrees.
The outer joint must not be bent more than
45 degrees.
ADO not damage the halfshaft oil seal.
Attach the right-hand halfshaft and the
intermediate shaft to the transaxle.
14' ACAUTION:~~ brake fluid is spilt on the
paintwork, the affected area must be
immediately washed down with cold water.
N0TE:Make sure the spring clip is correctly seated.
Connect the clutch slave cylinder supply
line.
Install the spring clip.
15. Attach the coolant expansion tank to the
bracket. 18.
N0TE:lnstall a
new center bearing cap and
locknuts.
Install the intermediate shaft center bearing
cap.
I. Install the center bearing cap.
2. Attach the heat shield.
3. Install the locknuts.
19. CAUTIONS:
Asupport the halfshaft. The inner joint
must not be bent more than 18 degrees.
The outer joint must not be bent more than
45 degrees.
2006.0 Fiesta 1212006 GI I 3293en
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308-03-66 Manual Transmission/'rransaxle 308-03-66
INSTALLATION
24. Attach the gearshift cables to the selector 27. Install the gearshift actuator cover.
levers.
Vehicles with automated gearshift
25. Connect the gearshift actuator electrical
connector (colored grey).
26. Connect the gearshift actuator electrical
connector (colored black).
28. Connect the clutch slave cylinder supply
line.
Install the clip.
All vehicles
29. Connect the reversing lamp switch
electrical connector.
30. Install the starter motor.
2006.0 Fiesta 1212006 GII 3293en
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308103168 Manual Transmission/Transaxle 308103168
INSTALLATION
37. Connect the powertrain control module
(PCM) electrical connector to the PCM.
38. Install the front wheels and tires. For
additional information, refer to
Section
204-04 wheels and Tires].
Vehicles without automated gearshift
39. Adjust the gearshift cables. For additional
information, refer to Section
308-00
[Manual Transmission/Transaxle and Clutch
- General Information].
40. Bleed the clutch system. For additional
information, refer to Section
308m00
[Manual Transmission/Transaxle and Clutch
- General Information].
All vehicles
41. Install the battery tray. For additional
information, refer to Section
41 4-01
[Battery, Mounting and Cables].
42. With the vehicle on a level surface, fill the
transaxle until the oil level is just below the
bottom of the filler hole.
Vehicles with automated gearshift
43m ACAUTION:T~~ worldwide diagnostic
system (WDS) gearshift actuator bleed
option must be carried out
if any part of the
clutch hydraulic system is opened or any
new components are installed.
N0TE:When the WDS gearshift actuator bleed
option is selected, the learn transmission and learn
clutch parameter options will automatically be
completed.
Bleed the clutch system. For additional
information, refer to Section
308-00 [Manual
Transmission/Transaxle and Clutch - General
Information].
2006.0 Fiesta 1212006 GII 3293en
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308-03-71 Manual Transmission/Transaxle 308-03-71
INSTALLATION
Attach the exhaust flexible pipe to the 15.
Remove the support wrap or suitable splint
catalytic converter. from
the exhaust flexible pipe.
i
3m ACAUTION:~~ brake fluid is spilt on the 16. lnstall the right-hand halfshaft.
paintwork, the affected area must be For additional information,
refer to: Front
immediately washed down with cold water. Halfshaft
RH (205-04 Front Drive
N0TE:Make sure the spring clip is correctly seated. Halfshafts, Removal and Installation).
Connect the clutch slave cylinder supply
17. lnstall the left-hand halfshaft.
line. For additional information,
refer to: Front
lnstall the spring clip. Halfshaft LH (205-04 Front Drive
Halfshafts, Removal and Installation).
18. lnstall the engine support insulator.
14. Raise and support the vehicle. For
additional information, refer to: (I
00-02
Jacking and Lifting)
19. Install the accessory drive belt cover.
Jacking (Description and Operation),
Lifting (Description and Operation).
2006.0 Fiesta 1212006 G453417en
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308-03-74 Manual Transmission/Transaxle 308-03-74
INSTALLATION
34. Adjust the gearshift cables.
For additional information, refer to:
Gearshift Cable Adjustment
(308-00
Manual Transmission/Transaxle and
Clutch
- General Information, General
Procedures).
35. Bleed the clutch system.
For additional information, refer to: Clutch
System Bleeding (308-00 Manual
Transmission/Transaxle and Clutch -
General Information, General Procedures).
36, Install the battery tray.
For additional information, refer to: Battery
Tray
- 2.OL Duratec-HE (M14) (414-01
Battery, Mounting and Cables, Removal
and
Installation).
37. With the vehicle on a level surface, fill the
transaxle until the fluid level is just below
the bottom of the filler hole.
2006.0 Fiesta 1212006 G453417en
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Manual Transmission/Transaxle External
308-06-5 Controls
308-06-5
External Controls
Inspection and Verification 4. If an obvious cause for an observed or reported
concern is found, correct the cause (if possible)
1. Verify the customer concern. before proceeding to the next
step.
2. Visually inspect for obvious signs of mechanical 5.
If the concern is not visually evident, verify the
damage. symptom
and refer to the Symptom Chart.
3. Make sure that the gearshift cables are correctly
routed and not under any tension from other
components.
Symptom Chart
Symptom
External controls do not
operate freely. Possible Sources
Action
Gearshift cables incorrectly
adjusted.
Gearshift lever damaged.
Selector mechanism damaged.
Gearshift cables damaged. ADJUST
the gearshift cables.
REFER to: Gearshift Cable
Adjustment
- Vehicles With:
5-Speed Manual Transaxle
(iB5) (308-00 Manual Trans-
mission/Transaxle and Clutch
- General Information,
General Procedures).
GO to Pinpoint Test A.
Pinpoint Tests
PINPOINT TEST A : STIFF GEARSHIFT
TEST CONDITIONS
DETAILSIRESU LTSIACTIONS
Al: CHECK THE GEARSHIFT LEVER
Detach the gearshift cables from the gearshift
lever.
Is the gearshift lever difficult to operate?
+ Yes
Install a new gearshift lever.
REFER to: Gearshift Lever (308-06 Manual
TransmissionlTransaxle External Controls,
Removal and Installation).
-, No
GO to
A2.
A2: CHECK THE GEARSHIFT CABLES
Attach the gearshift cables to the gearshift lever.
2006.0 Fiesta IZIZOO~ G37664en
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