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Output Shaft - Vehicles Built From: 08-2000 > < Input Shaft

Focus 1999 (08.1998-12.2004)

Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75) - Output Shaft—Vehicles Built Up To: 07/2000 Focus 1999 (08/1998-12/2004)
Disassembly and Assembly of Subassemblies

Special Tool(s)

Remover, bearing (basic tool)

205-295 (15-050A)

Collet for 15-050 A/205-295

308-197 (16-062)

Separating tool, bearing/gear wheel

205-310 (15-091)
General Equipment
Press
Materials
Name
Specification
Transmission fluid
WSD-M2C200-C 

Disassembly

  1. CAUTION:
    CAUTION:The inner synchronizer ring and the synchronizer cone must be handled very carefully.
    General note

  1. Press off the transmission housing roller bearing together with the reverse gear wheel using the special tool.

  1. Remove the reverse gear synchronizer ring.
    1. Remove the needle roller bearing.
    1. Remove the synchronizer ring.

  1. NOTE:
    NOTE:Discard the snap ring.
    Remove the 5th/reverse gear synchronizer assembly.
    1. Remove the snap ring.
    1. Remove the complete synchronizer assembly.

  1. Remove the 5th gear wheel with the synchronizer ring and needle roller bearing.
    1. Synchronizer ring.
    1. Gear wheel (5th gear)
    1. Needle roller bearing

  1. Remove the taper roller bearing at the clutch end.

  1. CAUTION:
    CAUTION:The output shaft and the output pinion are a pair and may only be renewed as a pair.
    NOTE:
    NOTE:Discard the snap ring.
    Remove the output pinion and 1st gear wheel.
    1. Remove the snap ring.
    1. Press off the output pinion and 1st gear wheel together.

  1. Detach the double synchronizer and the needle roller bearing together.
    1. Needle roller bearing
    1. Inner synchronizer ring
    1. Synchronizer cone
    1. Outer synchronizer ring

  1. NOTE:
    NOTE:Discard the snap ring.
    Attach the synchronizer assembly for the 1st/2nd gear complete.
    1. Snap ring
    1. Complete synchronizer assembly

  1. Remove the double synchronizer together with the 2nd gear wheel.
    1. Outer synchronizer ring
    1. Synchronizer cone
    1. Inner synchronizer ring
    1. Gear wheel (2nd gear)
    1. Needle roller bearing

  1. CAUTION:
    CAUTION:Carefully pull the selector ring from the synchroniser hub. The detent balls are under spring pressure.
    NOTE:
    NOTE:Mark the location of the selector ring.
    Dismantle the synchronizer assembly.
    1. Pull off the selector ring.
    1. Synchronizer hub
    1. Compression spring
    1. Blocker bar
    1. Detent ball

Assembly

  1. NOTE:
    NOTE:Do not oil taper roller bearings which are to be used again. Install new taper roller bearings (untreated).
    Carefully clean and check all parts and coat with transmission fluid before reassembly.

  1. Attach the 2nd gear wheel with double synchronizer and needle roller bearing.
    1. Needle roller bearing
    1. Gear wheel (2nd gear)
    1. Inner synchronizer ring
    1. Synchronizer cone
    1. Outer synchronizer ring

  1. NOTE:
    NOTE:Note the markings.
    Assemble the gear synchronizer for the 1st/2nd gear.
    1. Insert the compression springs.
    1. Insert the blocker bar with detent balls against the spring pressure.
    1. Install the selector ring the right way round and slide it on.

  1. NOTE:
    NOTE:Attach the synchronizer hub with the small collar and the annular groove facing outwards (towards the 1st gear).
    Installation position of 1st/2nd gear synchronizer assembly Installation position of 1st/2nd gear synchronizer assembly

  1. Install the gear synchronizer for the 1st/2nd gear complete.
    1. Synchronizer assembly.
    1. Install a new snap ring.

  1. Attach the 1st gear wheel and double synchronizer together.
    1. Outer synchronizer ring
    1. Synchronizer cone
    1. Inner synchronizer ring
    1. Gear wheel (1st gear)
    1. Needle roller bearing

  1. CAUTION:
    CAUTION:The output pinion can only be installed on the splines in one position.
    Press on the output pinion.
    • Install the output pinion with the marking pointing upwards.
    1. Press on the output pinion using a suitable piece of tube and the press.
    1. Install a new snap ring.

  1. Press the taper roller bearing on at the clutch end.
    • Press on the taper roller bearing with a suitable length of tube and a press.

  1. Attach the 5th gear wheel with synchronizer ring and needle roller bearing.
    1. Needle roller bearing
    1. Gear wheel (5th gear)
    1. Synchronizer ring.

  1. NOTE:
    NOTE:Note the markings.
    Assemble the 5th/reverse gear synchronizer.
    1. Insert the compression springs.
    1. Insert the blocker bar with detent balls against the spring pressure.
    1. Install the selector ring the right way round and slide it on.

  1. NOTE:
    NOTE:Attach the synchronizer hub with the small collar and the annular groove facing outwards (towards the reverse gear wheel).
    Installation position of 5th/reverse gear synchronizer assembly

  1. Attach the complete 5th/reverse gear synchronizer assembly.
    1. Synchronizer assembly.
    1. Install a new snap ring.

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

  1. Press on the taper roller bearing at the transmission end.
    • Press on the taper roller bearing with a suitable length of tube and a press.

Output Shaft - Vehicles Built From: 08-2000 > < Input Shaft