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Disassembly and Assembly of Subassemblies > < Transaxle - 1.8L Diesel

Focus 1999 (08.1998-12.2004)

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

Special Tool(s)

Puller, bearing outer races

205-078 (15-048)

Adapter

205-078-01 (15-048-01)

Remover, bearing outer races

205-176 (15-074)

Assembly stand, engine/differential

205-329 (15-105A)

Mounting bracket (use with with 303-435)

303-435-06 (21-031B)

Puller, driveshaft oil seal

308-208 (16-074)

Disassembly

All vehicles
  1. NOTE:
    NOTE:1.8L Endura-DI available from 99¼ MY.
    Attach special tools.
Vehicles built up to 01/2000
  1. NOTE:
    NOTE:Shift the gearshift mechanism to neutral.
    Remove the gearshift mechanism.
    • Unscrew the bolts.
    • Lever off using a screwdriver.
Vehicles built from 02/2000
  1. Detach the shift mechanism cover.

  1. NOTE:
    NOTE:Shift the gearshift mechanism to neutral.
    Remove the gearshift mechanism.
All vehicles
  1. Pull out the front driveshaft oil seals using special tool.
Vehicles with diesel engine
  1. NOTE:
    NOTE:Only necessary if rectifying a leak.
    Remove the speedometer drive pinion.
Vehicles with 2.0L engine
  1. NOTE:
    NOTE:Only necessary if rectifying a leak.
    Remove the vehicle speed sensor (VSS).
All vehicles
  1. NOTE:
    NOTE:Do not drive out the dowel pins.
    Unscrew the transmission housing bolts.

  1. CAUTION:
    CAUTION:Take care not to damage the transmission housing.
    Separate the transmission housing.
    1. Use supports.
    1. Separate the transmission housing using two tire levers.

  1. NOTE:
    NOTE:Tip the differential slightly.
    Remove the differential assembly.
    • Remove the magnetic disc.

  1. Remove the 1st/2nd gear selector shafts and selector fork.

  1. Remove the selector forks.
    1. Swing the 5th/reverse gear selector fork to the side and remove it.
    1. Turn the 3rd/4th gear shift fork and remove it.

  1. Remove the snap ring from the reverse gear idler.

  1. Remove the input and output shafts.
    • Lift out the input and output shafts from the transmission housing together.
    • Take out the reverse gear idler with needle roller bearing and thrust washers.

  1. Remove the differential bearing outer race.
    • Attach special tool in housing recesses.

  1. Remove the bearing outer races from the input and output shafts.
    • Attach special tool in housing recesses.
  1. Clean and degrease the input shaft splines.

  1. CAUTION:
    CAUTION:Do not allow brake fluid to come into contact with the skin or eyes. If brake fluid does come into contact with your skin or eyes, rinse the affected areas with water immediately. Failure to observe these instructions can result in serious injury.
    CAUTION:
    CAUTION:Apply adhesive tape over the splines of the input shaft to prevent the input shaft seal being damaged.
    NOTE:
    NOTE:Discard the clutch slave cylinder.
    Remove the clutch slave cylinder (with thrust bearing).
  1. Remove the adhesive tape from the input shaft splines.

  1. Remove the bearing outer races with shim from the differential and the input shaft.
    • Attach special tool in housing recesses.

  1. Remove the output shaft bearing outer race together with shim.
    • Attach special tool in housing recesses.

  1. NOTE:
    NOTE:Only in case of damage or leaks.
    Remove the reverse gear idler shaft.

  1. NOTE:
    NOTE:Only in case of damage or leaks.
    Remove the reverse gear idler shaft.
    • Drive out the shaft using a solid piece of wood.

Disassembly and Assembly of Subassemblies > < Transaxle - 1.8L Diesel