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Ford Workshop Service and Repair Manuals

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Output Shaft > < Transaxle

Focus RS 2003 (09.2002-)

Manual Transmission/Transaxle - 2.0L Duratec-RS (Zetec) - Input Shaft Focus RS 2003 (09/2002-)
Disassembly and Assembly of Subassemblies

Special Tool(s)

Remover, Bearing (Main Tool)

205-295 (15-050A)

Collet for 205-295

308-195 (16-060)

Collet for 205-295

308-196 (16-061)

Support Plate, Gear Removal

308-198 (16-063)

Support Plate, Gear Removal (Dia 81.2 mm)

308-230 (16-077)
Materials
Name
Specification
Manual transmission fluid
WSD-M2C200-C 

Disassembly
  1. Using the special tools, remove the clutch housing roller bearing.

  1. NOTE:
    NOTE:When the roller bearing and the fifth gear wheel are removed together, refer to the following steps.
    Using the special tools, remove the transaxle housing roller bearing.

  1. Using the special tool and a suitable press, remove the fifth gear wheel and the transaxle housing roller bearing.
    1. Slide the snap ring up out of the annular groove until it sits below the roller bearing.
    1. Using the special tool, remove the gear wheel, snap ring and the roller bearing.
    • Discard the snap ring.

  1. Remove the fourth gear wheel.
    1. Remove the gear wheel.
    1. Remove the needle roller bearing.
    1. Remove the synchronizer ring.

  1. Remove the third and fourth gear synchronizer.
    • Remove and discard the snap ring.

  1. NOTE:
    NOTE:Mark the position of the selector ring in relation to the synchronizer hub to aid installation. Components are paired.
    NOTE:
    NOTE:The detent balls are spring-loaded. Take care when removing the selector ring from the synchronizer hub.
    Disassemble the third and fourth gear synchronizer.
    1. Remove the selector ring.
    1. Remove the compression springs, blocker bars and detent balls.

  1. Remove the third gear wheel.
    1. Remove the synchronizer ring.
    1. Remove the third gear wheel.

Assembly

  1. NOTE:
    NOTE:Lubricate the synchronizer rings with manual transmission fluid before assembly.
    NOTE:
    NOTE:When installing new roller bearings, oil the roller bearings after the shimming process.
    NOTE:
    NOTE:When installing the original roller bearings, check all parts carefully and lubricate them with manual transmission fluid.
    Carefully clean and check all sliding parts and lubricate them with clean manual transmission fluid before assembly.

  1. Using a length of suitable tube, install the clutch housing roller bearing.

  1. Install the third gear wheel.
    1. Install the third gear wheel.
    1. Install the third gear synchronizer ring.

  1. NOTE:
    NOTE:Observe the markings.
    Assemble the third and fourth gear synchronizer assembly.
    1. Install the compression springs.
    1. Install the blocker bars and detent balls.
    1. Install the selector ring.

  1. NOTE:
    NOTE:Install the third and fourth gear synchronizer with the large collar facing outwards (towards to the fourth gear wheel).
    NOTE:
    NOTE:Install a new snap ring.
    Install the third and fourth gear synchronizer assembly.
    1. Install the synchronizer assembly.
    1. Install the snap ring.

  1. Install the fourth gear wheel assembly.
    1. Install the synchronizer ring.
    1. Install the needle roller bearing.
    1. Install the gear wheel.

  1. NOTE:
    NOTE:Install the fifth gear wheel with the large collar facing outwards.
    NOTE:
    NOTE:Install a new snap ring.
    Using a length of suitable tube, install the fifth gear wheel.

  1. Using a suitable length of suitable tube, install the transaxle housing roller bearing.

Output Shaft > < Transaxle