ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

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Transaxle - Vehicles Built From: 08-2000 > < Differential

Focus 1999 (08.1998-12.2004)

Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (iB5) - Transaxle—Vehicles Built Up To: 07/2000 Focus 1999 (08/1998-12/2004)
Assembly

Special Tool(s)

Installer, Rear Hub Bearing Cone/Oil 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)

Installer, Halfshaft Oil Seal

308-039 (16-018)

Installer, Input Shaft Bearing Cone

308-041 (16-020)

Installer, Extension Housing Bushing/Oil Seal

308-045 (16-015)

Installer, Input Shaft Snap Ring

308-076 (16-031)
General Equipment
Press
Dial indicator gauge
Magnetic base for dial indicator gauge
Auxiliary plug
M8 x 50mm bolt
Center punch
Materials
Name
Specification
Transmission fluid
WSD-M2C200-C
Sealer
WSK-M2G348-A5
Universal sealer
ESEE-M4G1008-A
Silicon sealer
WSE-M4G323-A4
High-temperature grease
ESD-M1C220-A

Assembly

  1. Clean and check all parts carefully before reassembly.

  1. CAUTION:
    CAUTION:Install the output shaft roller bearings with the inscribed side facing upwards.
    Install the output shaft roller bearing and the bearing outer race with the special tool.
    1. Install the oil thrower.
    1. Install the output shaft roller bearing.

  1. Install the differential bearing outer race using the special tool.

  1. Install the 5th/reverse gear selector shaft with shift locking bush.
    1. Shift locking bush
    1. 5th/reverse gear selector shaft

  1. Install the reverse idler gear.

  1. Install the differential and permanent magnet.

  1. Prepare input and output shafts for installation.
    1. Engage the input shaft and output shaft.
    1. Position the 1st/2nd gear selector fork.
    1. Position the 3rd/4th gear selector fork.

  1. NOTE:
    NOTE:Attach a rubber band to the selector shaft as an aid to assembly.
    Install the input and output shafts.
    • Insert the input shaft to a depth of approx. 50 mm and move slightly to one side.
    • Insert the output shaft level with the input shaft and engage the gear wheels again.
    • Install the input and output shafts.

  1. NOTE:
    NOTE:Replace the lower snap ring.
    Install the selector shaft guide sleeve and lower snap ring.
    1. Install the selector shaft guide sleeve.
    1. Install the lower snap ring.

  1. NOTE:
    NOTE:Replace the upper snap ring.
    Attach the upper snap ring for the selector shaft guide sleeve.
    1. Lift the guide sleeve.
    1. Install the upper snap ring.

  1. Shift the gearshift mechanism to 5th gear.
    • Turn the selector shaft clockwise until the reverse gear/5th gear shift alley is reached, then press downwards.

  1. Install a 3.8 mm measuring shim and secure using a center punch.
    1. Transmission housing
    1. Measuring shim
    1. Bearing outer race

  1. NOTE:
    NOTE:Thoroughly clean the transmission housing mating faces.
    Assemble the transmission housing.
    • Tighten the bolts.
    • Turn the transmission through 180 degrees.

  1. Attach the special tools.
    • Remove the auxiliary plugs.

  1. Prepare the differential for measuring.
    • Turn the differential approx. ten times to settle the bearings.

  1. NOTE:
    NOTE:Carry out the measurement 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. Raise the differential using the special tool.
    1. Note the resulting measurement (e.g. 0.73 mm).
    • Example: 0.73 mm + 0.74 mm + 0.72 mm divided by three = 0.73 mm.

        • 1. The thickness of the adjusting shims must be rounded down to the nearest tenth of a millimeter if the attained value is 0.05 mm or less and rounded up if the attained value is 0.06 mm or more.
  1. Calculate the required adjustment shim thickness.
    • Adjustment shim thickness = measuring shim (3.80 mm) + average value (0.73 mm) + bearing preload (0.14 mm) - thickness of 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 adjusting shim thickness is 0.2 mm (rounded off to 0.25 mm).

  1. Separate the transmission housing sections.
    • Turn the transmission through 180 degrees.
    • Detach the dial indicator gauge with the magnetic base and the special tools.

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

  1. NOTE:
    NOTE:The inner diameters of the Belleville washers contact one another.
    Install the adjusting shim determined and secure using a center punch.
    1. Install the Belleville washers.
    1. Install adjusting shim of determined thickness.
    1. Install the bearing race.

  1. Evenly coat the inner edge of the transmission housing mating face with sealer

  1. Assemble the transmission housing and tighten the bolts evenly.

  1. NOTE:
    NOTE:Replace the snap rings for the input and output shafts.
    Carefully lift the input and output shafts and install the snap rings.

  1. NOTE:
    NOTE:Turn the snap rings so that they are located in the cut-outs in the gasket.
    NOTE:
    NOTE:Replace the 5th gear housing gasket.
    Install the 5th gear housing gasket.

  1. Install the 5th gear housing.
  1. Detach the transmission from the assembly stand.

  1. NOTE:
    NOTE:The transmission housing must not sit on the press table. Support the assembly on the splined clutch input shaft on the press table.
    Press on the 5th gear wheel using the special tool and a suitable press.
  1. Mount the transmission on the mounting stand.

  1. NOTE:
    NOTE:Replace the snap ring for the 5th gear wheel.
    Attach the snap ring for the 5th gear wheel.
    1. Fit the snap ring onto the special tool.
    1. Position the special tool and push on the snap ring.

  1. NOTE:
    NOTE:Only perform the installation in neutral.
    Installation position for selector shaft interlock mechanism.

  1. NOTE:
    NOTE:Only perform the installation in neutral.
    Install the selector shaft interlock mechanisms.

  1. NOTE:
    NOTE:Identification of synchronizer unit installation position.
    Assemble the 5th gear synchronizer unit.
    1. 5th gear wheel
    1. Synchronizer ring
    1. Synchronizer unit
    1. Retaining plate

  1. Install the 5th gear synchronizer unit with selector fork.
    1. Swivel the drive plate upwards.
    1. Push on the 5th gear synchronizer unit until it reaches the drive plate.

  1. NOTE:
    NOTE:Do not tighten the gear selector boss bolt at this stage.
    NOTE:
    NOTE:Replace the snap ring for the 5th gear synchronizer unit.
    NOTE:
    NOTE:Replace the gear selector boss retaining pin
    Install the 5th gear synchronizer unit and selector fork.
    1. Install the gear selector boss.
    1. Attach the snap ring for the 5th gear synchronizer unit.

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

  1. Attach the shift and selector cable brackets.

  1. NOTE:
    NOTE:The 5th gear interlock mechanism must be installed.
    Engage 5th gear.
    • Press down the selector fork and gear selector boss together.

  1. Engage 5th gear.
    • Turn the selector shaft clockwise to the stop.

  1. Engage 5th gear.
    • Turn the selector shaft clockwise to the stop and press it in.

  1. Adjust the gear selector boss.
    1. Turn the selector shaft clockwise and press it down.
    1. Raise the gear selector boss to eliminate the end float.
    1. Tighten the bolt in this position.

  1. Install the 5th gear housing end cover and install the input shaft oil seal using the special tool.
    1. Apply sealer to 5th gear housing end cover and install.
    1. Drive in the input shaft oil seal until it engages audibly.

  1. Attach the gearshift lever.
    1. Install the snap-ring.
    1. Fit the protective cap (if present).

  1. Attach the gearshift cable cover.

  1. Install the vehicle speed sensor (VSS) (if present).
    1. Install the VSS.
    1. Install the retaining pin.

  1. CAUTION:
    CAUTION:Wrap the input shaft splines with adhesive tape to protect the input shaft oil seal.
    Position the input shaft oil seal.

  1. CAUTION:
    CAUTION:Do not coat the clutch slave cylinder with high-temperature grease.
    Install the clutch slave cylinder.
    • Tighten the bolts evenly, pressing 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 lightly with grease
  1. Remove the transmission from the mounting stand.

Transaxle - Vehicles Built From: 08-2000 > < Differential