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Assembly|Installation > < Differential

Focus 1999 (08.1998-12.2004)

Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75) - Transaxle Focus 1999 (08/1998-12/2004)
Assembly

Special Tool(s)

Installer, bearing outer race and oil seal

204-017 (14-010)

Installer, bearing outer race and oil seal

204-050 (14-024)

Torque gauge

205-067 (15-041)

Bearing outer race installer

205-075 (15-036)

Installer, differential oil seal

205-115 (15-058)

Socket

205-175 (15-073)

Compressor, valve springs

303-060 (21-024)

Adaptor for 303-060

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

Adaptor for 303-060

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

Mounting plate for 303-435-06

303-435-14A (21-212A)

Installer, input shaft oil seal

307-210 (17-041)

Holding Fixture, Dial Indicator Gauge (Output Shaft End Play)

308-194B (16-059B)
General Equipment
Press
Dial indicator
Magnetic stand for dial indicator
Materials
Name
Specification
Transmission fluid
WSD-M2C200-C 
Sealer
WSK-M2G348-A5 
Slave cylinder sealer
ESK-M4G269-A 
High-temperature grease
ESDM-1C220-A 

Assembly

All vehicles
  1. NOTE:
    NOTE:1.8L Endura-DI available from 99¼ MY.
    Clean and check all parts carefully before reassembly.

  1. NOTE:
    NOTE:Only if removed
    Install the reverse gear idler shaft.
    1. Coat the mating face of the reverse gear idler shaft with sealer.
    1. Align the reverse gear idler shaft with the locating bolt and drive it in.
    1. Unscrew the locating bolt and screw in the original bolts.

  1. CAUTION:
    CAUTION:Maximum press force 15 kN.
    Fit the bearing cones on the transmission housing side.
    • Heat up the housing area to approximately 80°C using hot air blower.
    • Cool the bearing cones using temperature reduction spray and insert them.
    • Fit the bearing cones of the:
    • Input shaft with 307-210 (17-041)
    • output shaft using special tool 205-075 (15-036)
    • differential using special tool 204-050 (14-024)
  1. Measuring shim to be fitted:
    • Input Shaft: 1.00 mm
    • Output shaft: 1.00 mm
    • Differential: 1.10 mm

  1. CAUTION:
    CAUTION:Maximum press force 15 kN.
    Fit the measuring shims and the bearing cones in the housing section at the clutch end.
    • Heat up the housing area to approximately 80°C using hot air blower.
    • Cool the bearing cones using temperature reduction spray.
    1. Fit the measuring shims.
    1. Fit the bearing cones.
    • Fit the bearing cones of the:
    • Input shaft with 204-017 (14-010)
    • output shaft using special tool 205-075 (15-036)
    • differential using special tool 204-050 (14-024)

  1. NOTE:
    NOTE:Do not oil taper roller bearings which are to be used again. Install new taper roller bearings (untreated).
    Insert the input and output shafts in the transmission housing.
    • Engage fourth gear.
    • Assemble the input and output shafts and insert them in the transmission housing together.

  1. NOTE:
    NOTE:Do not oil taper roller bearings which are to be used again. Install new taper roller bearings (untreated).
    Insert the differential (1.8 Endura-DI shown).

  1. NOTE:
    NOTE:Check that the mating face is clean.
    Fit the housing (clutch end).
    • Fit special tool with longer bolt to the transmission housing flange.

  1. Install the housing sections (clutch end).
    • Tighten the 16 flange bolts uniformly.

  1. Attach the special tool.
    • Put the measuring plunger onto the fourth gear gearwheel.

  1. Prepare the input shaft for measuring.
    • Turn the input shaft back and forth approximately 20 times to settle the bearings.

  1. Set up the dial indicator.
    1. Install the special tool to the transaxle.
    1. Set up the magnetic dial indicator base.
    1. Set the dial indicator to "0".

  1. NOTE:
    NOTE:Carry out the previous step and this step three times and calculate the average measurement.
    Determine the input shaft end float.
    1. Lift the input shaft with the tyre lever.
    1. Note down the measurement (e.g. 0.22 mm).
    • Example: 0.22 mm + 0.23 mm + 0.21 mm divided by three = 0.22 mm.

  1. Prepare the output shaft for measuring.
    • Turn the output shaft back and forth 20 times to settle the bearings (see previous job step).
    • Set up the dial indicator.
    • Set the dial indicator to "0".

  1. NOTE:
    NOTE:Carry out both this and the following step three times and calculate the average measurement.
    Measure the output shaft end float.
    • Lift the output shaft using a tire lever and note down the measurement, e.g. 0.32 mm.
    • Example: 0.32 mm + 0.34 mm + 0.33 mm divided by three = 0.33 mm.

  1. Prepare the differential for measuring.
    • Turn the input shaft back and forth 20 times and, at the same time, press down the differential.
    • Set up the dial indicator and set it to "0".

  1. NOTE:
    NOTE:Carry out both this and the following step three times and calculate the average measurement.
    Measure the differential end float.
    • Raise the differential using the special tool, make a note of the measurement results e.g. 0,34 mm
    • Example: 0.34 mm + 0.36 mm + 0.38 mm divided by three = 0.36 mm
  1. Calculate the required input shaft shim thickness.
    • Required shim thickness 1.00 mm.
    • Measured end float (see previous step) 0,22 mm.
    • End float - 0.05 mm.
    • Required shim: 0.22 mm - 0.05 mm + 1.00 mm = 1.17 mm.
  1. Calculate the required output shaft shim thickness.
    • Required shim 1.00 mm.
    • Measured end float (see previous step) 0,33 mm.
    • Preload figure 0.13 mm.
    • Required shim: 1.00 mm + 0.33 mm + 0.13 mm = 1.46 mm.
  1. Calculate the required differential shim thickness.
    • Required shim thickness 1.10 mm.
    • Measured end float (see previous step) 0,36 mm
    • Preload figure 0.33 mm
    • Required shim: 1.10 mm + 0.36 mm + 0.33 mm = 1.79 mm.
  1. Remove the bearing cones again.
    • Remove the bearing cones of the:

        • 1. Input shaft

        2. output shaft

        3. differential

  1. Fit the shims and bearing cones.
    1. Fit the required shims.
    1. Fit the bearing cones of the:

        2. 1. Input shaft

        2. output shaft

        3. differential

  1. Fit the reverse idler gear.
    1. Lower thrust washer
    1. Needle roller bearing
    1. Reverse idler gear (smaller collar facing downwards)
    1. Upper thrust washer
    1. Snap-ring

  1. Install the input and output shafts together.

  1. Fit the selector fork.
    • Move the fourth gear shift ring to the neutral position.
    • Insert the 5th and reverse gear selector fork and swing it to the side.

  1. Install the third and fourth gear selector fork.
    • Swing the fifth and reverse gear selector fork back.

  1. NOTE:
    NOTE:Correctly seated selector shafts will be at the same height.
    Install the first and second gear selector fork and selector shafts.

  1. Install the differential (1.8 Endura-DI shown).
    1. Fit the differential assembly.
    1. Place the clean magnetic disc in the recess.

  1. Treat the mating face with sealer.
    • The sealing surfaces must be dry and free of oil or grease. Apply sealant evenly on the inside of the sealing surface (even bead of 2 mm diameter).

  1. NOTE:
    NOTE:The transmission housing must not be turned over to tighten the bolts.
    Fit the housing (clutch end).
    • Tighten the 16 flange bolts within 15 minutes, working diagonally across.
Vehicles built up to 01/2000
  1. NOTE:
    NOTE:Make sure the transmission is in neutral (the gearshift lever and selector lever must be vertical).
    Fit the selector mechanism.
    • The sealing surfaces must be dry and free of oil or grease. Apply sealant evenly on the outside of the sealing surface (even bead of 2 mm diameter).
    1. Bolt, M8 x 35 mm.
    1. Bolt, M8 x 85 mm.
Vehicles built from 02/2000
  1. NOTE:
    NOTE:Make sure the transmission is in neutral (the gearshift lever and selector lever must be vertical).
    Fit the selector mechanism.
    • The sealing surfaces must be dry and free of oil or grease. Apply sealant evenly on the outside of the sealing surface (even bead of 2 mm diameter).

  1. Install the shift mechanism cover.
All vehicles
  1. Measure the turning torque.
    • Engage fourth gear.
    • Measure the turning torque.
    • If the turning torque is too high, all the measurements (to establish the required shim thickness) must be repeated.
Vehicles with diesel engine
  1. Fit the speedometer drive pinion.
    • Insert the drive pinion.
    • Carefully drive in the roll pin.
Vehicles with 2.0L engine
  1. Install the vehicle speed sensor (VSS).
All vehicles
  1. Install the front halfshaft oil seals.

  1. WARNING:
    WARNING:Do not allow brake fluid to come into contact with the skin or eyes. If brake fluid contacts the skin or eyes, rinse the affected area immediately with water. Failure to observe these instructions can lead to injury.
    CAUTION:
    CAUTION:Apply adhesive tape over the splines of the input shaft to prevent the input shaft oil seal being damaged.
    CAUTION:
    CAUTION:Do not lubricate the clutch slave cylinder.
    NOTE:
    NOTE:Install new clutch slave cylinder.
    Install the clutch slave cylinder using a new seal and slave cylinder sealant.
  1. Remove the adhesive tape from the input shaft splines.
  1. Coat the input shaft splines with a thin coating of high-temperature grease.

Assembly|Installation > < Differential