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Synchronizers > < Input Shaft

Cougar 1999 (08.1998-01.2001)

Manual Transmission/Transaxle - Output Shaft Cougar 1999 (08/1998-01/2001)
Disassembly and Assembly of Subassemblies

Special Tool(s)

Remover, Bearing Main Tool

205-295 (15-050A)

Collet for 205-295

308-197 (16-062)
Materials
Name
Specification
Manual transmission fluid
WSD-M2C200-C 

Disassembly

CAUTION:
CAUTION:The inner synchronizer ring and the synchronizer cone must be handled very carefully.
NOTE:
NOTE:If a new transaxle housing, or any new bearings or shafts are installed, the transaxle must be shimmed.
  1. Using the special tool, remove the taper roller bearing.

  1. Remove the reverse gear wheel.
    1. Reverse gear wheel
    1. Needle roller bearing
    1. Synchronizer ring

  1. Remove the fifth/reverse gear synchronizer assembly.
    1. Snap ring
    1. Synchronizer assembly

  1. Remove the fifth gear wheel.
    1. Synchronizer ring
    1. Fifth gear wheel
    1. Bearing

  1. Using the special tool, pull the taper roller bearing off the output shaft.

  1. CAUTION:
    CAUTION:Note the marks on the output pinion for reinstallation. The output shaft and output pinion belong together and can only be installed new as a pair.
    Using the special tool, remove the output pinion and first gear.
    1. Remove the snap ring.
    1. Remove the output pinion and first gear wheel together.

  1. Remove the double synchronizer.
    1. Needle roller bearing
    1. Inner synchronizer ring
    1. Synchronizer cone
    1. Outer synchronizer ring

  1. Remove the first/second gear synchronizer assembly.
    1. Snap ring
    1. Synchronizer assembly

  1. Remove the double synchronizer together with the second gear wheel.
    1. Outer synchronizer ring
    1. Synchronizer cone
    1. Inner synchronizer ring
    1. Second gear wheel
    1. Needle roller bearing

Assembly

CAUTION:
CAUTION:Immerse the double synchronizer units in a bath of manual transmission fluid before installation.
  1. Carefully clean and check all sliding parts and lubricate them with manual transmission fluid before installation.

  1. NOTE:
    NOTE:Do not oil taper roller bearings which are to be used again.
    Install the second gear wheel with the double synchronizer and needle roller bearing.
    1. Needle roller bearing
    1. Second gear wheel
    1. Inner synchronizer ring
    1. Synchronizer cone
    1. Outer synchronizer ring

  1. NOTE:
    NOTE:Install the synchronizer ring hub with the small collar and the annular groove of the selector ring facing outwards.
    Installation position of the synchronizer assembly.

  1. NOTE:
    NOTE:Installation position see previous step.
    Install the first/second gear synchronizer assembly.
    1. Synchronizer assembly
    1. New snap ring

  1. NOTE:
    NOTE:Installation position see previous step.
    Install the double synchronizer together with the first gear wheel.
    1. Outer synchronizer ring
    1. Synchronizer cone
    1. Inner synchronizer ring
    1. First gear wheel
    1. Needle roller bearing

  1. CAUTION:
    CAUTION:The output pinion can only be installed on the shaft splines in one position.
    NOTE:
    NOTE:Install the output pinion with the mark facing upwards.
    Install the output pinion.
    1. Using a suitable driver, install the output pinion.
    1. Install a new snap ring.

  1. Install the taper roller bearing on the output shaft.
    • Using a suitable driver, install the bearing.

  1. Install the fifth gear wheel.
    1. Bearing
    1. Fifth gear wheel
    1. Synchronizer ring

  1. NOTE:
    NOTE:Install the synchronizer hub with the small collar and the annular groove running round it facing outwards.
    Installation position of the synchronizer assembly.

  1. Install fifth/reverse gear synchronizer assembly
    1. Synchronizer assembly
    1. New snap ring

  1. Install the reverse gear wheel.
    1. Synchronizer ring
    1. Bearing
    1. Reverse gear wheel

  1. Install the taper roller bearing.
    • Using a suitable driver, install the bearing.

Synchronizers > < Input Shaft