FORD FIESTA 2007 Workshop Manual

308-03-51 Manual Transmission/Transaxle 308-03-51
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
4. Selector plate.
2006.0 Fiesta 1212006 Gl8lllen
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308-03-52 Manual Transmission/Transaxle 308-03-52
ASSEMBLY
Transaxle(l6 11 8 8)
Special Tool(s)
Installer, Wheel Hub Bearing
Conelseal
205-296 (1 5-085)
15085
I I Adapter for 303-060 I
21 02402
Mounting Stand
303-435 (2 1 -1 87)
Adapter for
303-060
303-060-02 (2 1 -024-02)
I I Installer, Halfshaft Seal
Special Tool(s)
Installer, lnput Shaft Bearing
308-041 (1 6-020)
I I Installer, Extension Housing I
1 press I
16031
I Dial indicator gauge I
Installer, lnput Shaft Snap
Ring
308-076 (1 6-03 1
)
I Magnetic stand for dial indicator gauge
Seneral Equipment
I Blanking plugs I
I M8 x 50 mm bolt I
Thread die
Materials
Name Specification
1 Sealant I ESEE-M4G1008-A I
1 Transmission Oil I WSD-M2C200-C I
I Oil Pan Sealer I WSK-M2G348-A5 I
I Silicon Sealer I WSE-M4G323-A4 I
High Temperature
Grease
1. Clean and check all parts carefully before
reassembly.
Apply clean transmission oil to all running
surfaces.
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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.
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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.
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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.
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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.
- -
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308-03-57 Manual Transmission/Transaxle 308-03-57 I I
ASSEMBLY
21. Apply sealer on the inside edge of the Install
the fifth gear housing gasket.
1. transaxle housing mating face.
22. Assemble the transaxle housing and tighten 26m ACAUTION:M~~~ sure the snap rings are
in the correct position. Failure to follow this
the bolts.
instruction may cause damage to the fifth
23. N0TE:lnstall new input and output shaft
snap rings. gear
housing.
Turn the snap rings to the position shown.
Raise the and shafts 'lightly 27. NOTE:lnstall new fifth gear housing
and install the snap rings.
retaining bolts.
' 24. Using a suitable thread die, clean all the Install
the fifth gear housing.
-I hole threads in the fifth gear housing.
25. N0TE:lnstall a new fifth gear housing 28. Remove the transaxle from the mounting
stand.
gasket.
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308-03-58 Manual Transmission/Transaxle 308-03-58
ASSEMBLY
29. N0TE:The transaxle housing must not Correct installation position for the selector
contact the press table. Support the input shaft interlock mechanism.
shaft splines.
Using the special tool and a suitable press,
install the fifth gear.
33. Install the selector shaft interlock
mechanism.
Apply sealant to the thread.
30. Mount the transaxle on the mounting stand.
31. N0TE:lnstall a new fifth gear snap ring.
Install the fifth gear snap ring.
1. Install the snap ring onto the special tool.
2. Install the special tool and push on the snap
ring.
34. N0TE:Align the gear synchronizer to the
marks.
Assemble the fifth gear synchronizer.
I. Fifth gear.
2. Synchronizer ring.
3. Synchronizer assembly.
32. Make sure that the selector shaft is in the 4. Retaining plate.
neutral position.
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308-03-59 Manual Transmission/Transaxle 308-03-59
ASSEMBLY
35. N0TE:lnstall a new fifth gear synchronizer
assembly snap ring.
1 , N0TE:Use a new selector fork retaining pin.
lnstall the fifth gear synchronizer assembly
and the selector fork.
lnstall the retaining pin.
lnstall the snap ring.
36. Apply sealer evenly to the inside edge of
the fifth gear housing mating face.
37. lnstall the fifth gear housing cover.
38. lnstall the selector lever.
lnstall the bellows.
39. Engage the fifth gear.
Turn the selector shaft clockwise as far as
possible and push the shaft in.
40. N0TE:lnstall new halfshaft oil seals.
Using the special tools, install both halfshaft
oil seals (left-hand side shown).
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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.
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