ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

ABOUT US
Assembly|Installation > < Selector Plate

C-MAX 2003.75 (06.2003-)

Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (iB5) - Transaxle C-MAX 2003.75 (06/2003-)
Assembly

Special Tool(s)

Installer, Wheel Hub Bearing Cone/Seal

205-296 (15-085)

Compressor, Valve Spring

303-060 (21-024)

Adapter for 303-060

303-060-02 (21-024-02)

Adapter for 303-060

303-060-07 (21-024-07)

Mounting Stand

303-435 (21-187)

Installer, Halfshaft Seal

308-039 (16-018)

Adapter for 308-039

308-039-01

Installer, Input Shaft Bearing Cone

308-041 (16-020)

Installer, Extension Housing Bushing/Seal

308-045 (16-015)

Installer, Input Shaft Snap Ring

308-076 (16-031)
General Equipment
Press
Dial indicator gauge
Magnetic stand for dial indicator gauge
Blanking plugs
M8 x 50 mm bolt
Thread die
Materials
Name
Specification
Sealant
ESEE-M4G1008-A 
Transmission Oil
WSD-M2C200-C
Oil Pan Sealer
WSK-M2G348-A5
Silicon Sealer
WSE-M4G323-A4
High Temperature Grease
ESDM-1C220-A
  1. Clean and check all parts carefully before reassembly.

  1. CAUTION:
    CAUTION:Make sure the output shaft roller bearing is installed with the scribed text uppermost.
    Using the special tool, install the output shaft roller bearing and the output shaft bearing cup.
    1. Install the oil funnel.
    1. Install the output shaft roller bearing.

  1. Using the special tool, install the differential bearing cup.

  1. Install the fifth and reverse gear selector shaft, and the shift lock.
    1. Install the shift lock.
    1. Install the fifth and reverse gear selector shaft.

  1. Install the reverse gear idler.

  1. Install the differential assembly and the permanent magnet.

  1. Prepare the input and output shaft for installation.
    1. Engage the input shaft and output shaft.
    1. Move the first and second gear shift forks to the installation position.
    1. Move the third and fourth gear shift forks to the installation position.

  1. NOTE:
    NOTE:Install a rubber band to the second selector shaft to aid assembly.
    Install the input shaft, the output shaft and the selector forks.
    • Insert the input shaft to a depth of 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.
    • Install the input shaft and the output shaft.

  1. NOTE:
    NOTE:Install a new snap ring.
    Install the selector shaft guide sleeve lower snap ring.
    1. Install the guide sleeve.
    1. Install the snap ring.

  1. NOTE:
    NOTE:Install a new snap ring.
    Install the selector shaft guide sleeve upper snap ring.
    1. Lift the guide sleeve.
    1. Install the snap ring.

  1. 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.

  1. Install the 3.8 mm thick measuring shim and secure it with a punch mark.
    1. Transaxle housing.
    1. Measuring shim.
    1. Bearing cup.

  1. NOTE:
    NOTE:Make sure that the transaxle housing mating surfaces are clean.
    Assemble the transaxle housing.
    • Install the bolts.
    • Turn the transaxle 180 degrees.

  1. Install the special tools.
    • Remove the blanking plugs.

  1. Prepare the differential for measuring.
    • Turn the differential assembly approximately ten times to settle the bearings.
    • Pre-tension the dial indicator gauge by a minimum of 1 mm.

  1. NOTE:
    NOTE:Carry out the measuring procedure three times and calculate the average value.
    NOTE:
    NOTE:The adjusting shims are available from 0.1 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.
    1. Note the resulting measurement.
    • Example: 0.73 mm + 0.74 mm + 0.72 mm divided by three = 0.73 mm.

        • 1. The value of the thickness of the shim should be rounded down to the nearest tenth of a millimeter below if the value ends in 0.05 mm and below, and rounded up to the nearest tenth of a millimeter if the value ends in 0.06 mm and above.

  1. 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)

        • 1. 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).

  1. Separate the transaxle housing.
    • Turn the transmission approximately 180 degrees.
    • Remove the dial indicator gauge, the magnetic stand and the special tools.

  1. Using the special tool, remove the differential bearing cup and the measuring shim.

  1. CAUTION:
    CAUTION:The Belleville washers must be installed with the inner diameter of both washers touching.
    Install the measured adjusting shim.
    1. Install the Belleville washers.
    1. Install the measured adjusting shim.
    1. Install the bearing cone.
    • Using a suitable center punch, secure the bearing cone.

  1. Apply sealer on the inside edge of the transaxle housing mating face.

  1. Assemble the transaxle housing and tighten the bolts.

  1. NOTE:
    NOTE:Install new input and output shaft snap rings.
    Raise the input and output shafts slightly and install the snap rings.
  1. Using a suitable thread die, clean all the hole threads in the fifth gear housing.

  1. NOTE:
    NOTE:Install a new fifth gear housing gasket.
    Install the fifth gear housing gasket.

  1. CAUTION:
    CAUTION:Make sure the snap rings are in the correct position. Failure to follow this instruction may cause damage to the fifth gear housing.
    Turn the snap rings to the position shown.

  1. NOTE:
    NOTE:Install new fifth gear housing retaining bolts.
    Install the fifth gear housing.
  1. Remove the transaxle from the mounting stand.

  1. NOTE:
    NOTE:The transaxle housing must not contact the press table. Support the input shaft splines.
    Using the special tool and a suitable press, install the fifth gear.
  1. Mount the transaxle on the mounting stand.

  1. NOTE:
    NOTE:Install a new fifth gear snap ring.
    Install the fifth gear snap ring.
    1. Install the snap ring onto the special tool.
    1. Install the special tool and push on the snap ring.

  1. Make sure that the selector shaft is in the neutral position.
    • Correct installation position for the selector shaft interlock mechanism.

  1. Install the selector shaft interlock mechanism.

  1. NOTE:
    NOTE:Align the gear synchronizer to the marks.
    Assemble the fifth gear synchronizer.
    1. Fifth gear.
    1. Synchronizer ring.
    1. Synchronizer assembly.
    1. Retaining plate.

  1. NOTE:
    NOTE:Install a new fifth gear synchronizer assembly snap ring.
    NOTE:
    NOTE:Use a new selector fork retaining pin.
    Install the fifth gear synchronizer assembly and the selector fork.
    • Install the retaining pin.
    • Install the snap ring.

  1. Apply sealer evenly to the inside edge of the fifth gear housing mating face.

  1. Install the fifth gear housing cover.

  1. Install the selector lever.
    • Install the bellows.

  1. Engage the fifth gear.
    • Turn the selector shaft clockwise as far as possible and push the shaft in.

  1. NOTE:
    NOTE:Install new halfshaft oil seals.
    Using the special tools, install both halfshaft oil seals (left-hand side shown).

  1. Install the gearshift cable bracket.

  1. NOTE:
    NOTE:Install a new snap ring.
    Install the gearshift lever.
    1. Install the snap ring.
    1. Install the protective cap (if equipped).

  1. Install the selector mechanism cover.

  1. Install the vehicle speed sensor (VSS) (if equipped).
    1. Push in the VSS.
    1. Install the retaining pin.

  1. CAUTION:
    CAUTION:Using suitable adhesive tape, cover the input shaft splines to prevent damage to the input shaft oil seal.
    Position the input shaft oil seal.

  1. CAUTION:
    CAUTION:Do not apply grease on any parts of the clutch slave cylinder.
    Install the clutch slave cylinder.
    • Tighten the bolts evenly. In doing so, press the input shaft oil seal into the transmission housing.
  1. Remove the adhesive tape from the input shaft splines.
  1. Coat the input shaft splines with a thin layer of grease.

Assembly|Installation > < Selector Plate