ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

ABOUT US
Disassembly and Assembly of Subassemblies > < Transaxle - 1.9L Diesel

Galaxy 2000.75 (04.2000-02.2006)

Manual Transmission/Transaxle - Vehicles With: 6-Speed Manual Transmission (MT350) - Transaxle Galaxy 2000.75 (04/2000-02/2006)
Disassembly

Special Tool(s)

Remover/Installer, King Pin Bushing

204-018 (14-011)

Installer, Rear Hub Bearing/Oil Seal

205-052 (15-016)

Adapter for 205-071 (Thrust Pad)

205-071-02 (15-026-51)

Flange Holding Wrench, Universal

205-072 (15-030A)

Remover, Drive Pinion Oil Seal

205-078 (15-048)

Adapter for 205-078 (Thrust Pad)

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

Remover, Bearing/Gear

205-310 (15-091)

Remover, Bearing/Gear

205-311 (15-092)

Mounting Bracket, Engine/Differential

205-329 (15-105A)

Compressor, Valve Spring

303-060 (21-024)

Adapter for 303-060

303-060-04 (21-024-04)

Installer/Aligner, Timing Cover Seal

303-256 (21-137)

Remover, Crankshaft Seal

303-293 (21-143)

Mounting Stand

303-435 (21-187)

Mounting Bracket for 303-435

303-435–06 (21-031B)

Adapter for 308-110 (Plate)

308-110-02 (16-041-02)

Remover, Halfshaft Oil Seal

308-208 (16-074)
General Equipment
Internal extractor
Two tire levers
Hot air gun
Remover
Materials
Name
Specification
M8 x 60 mm locating bolt (vehicles build up to 12/2002)
 
M8 x 100 mm locating bolt (vehicles build from 01/2003 onwards)
 

Disassembly

All vehicles
  1. NOTE:
    NOTE:All the bearings are paired and must not be mixed.
    NOTE:
    NOTE:Use vise jaws protectors for all operations in a vise.
    Mount the transaxle on the mounting stand.
Vehicles built up to 12/2002
  1. Drain the transaxle.
    • Remove the drain plug.
    • Allow the oil to drain into a suitable container.

  1. Remove the clutch slave cylinder bleed valve.
Vehicles built 01/2003 onwards
  1. Drain the transaxle.
    • Remove the drain plug.
    • Allow the oil to drain into a suitable container.

  1. Remove the clutch slave cylinder bleed valve.
All vehicles
  1. NOTE:
    NOTE:Check the clutch slave cylinder for fluid leaks or damage. Install new parts as necessary.
    Remove the clutch slave cylinder assembly.

  1. Using the special tool, remove the input shaft oil seal.

  1. Remove the vehicle speed sensor (VSS).
Vehicles built up to 12/2002
  1. Remove the reversing lamp switch.
  1. Shift the gearshift mechanism to neutral position.
Vehicles built 01/2003 onwards
  1. Remove the reversing lamp switch.
  1. Shift the gearshift mechanism to neutral position.

  1. Remove the selector interlock mechanism.
All vehicles
  1. Remove the abutment collar and the selector mechanism bracket.
    1. Remove the abutment collar.
    1. Remove the selector mechanism retaining nut.
    1. Remove the circlip.
Vehicles built up to 12/2002
  1. Remove the shift cover outer retaining bolts.
    • Discard the bolts.

  1. NOTE:
    NOTE:Remove the shift cover centre retaining bolt and install a M8 x 60 mm locating bolt.
    Remove the shift cover.
    • Discard the O-ring.
    • Remove the locating bolt.
All vehicles
  1. Remove the shift cover and selector shaft.
    1. Remove the locking bolt.
    1. Remove the shift cover.
    • Pull out the selector shaft.

  1. Remove the selector shaft oil seal.

  1. Using the special tool, remove the ball sleeve.
    • Discard the O-ring.

  1. NOTE:
    NOTE:Move the selector forks, shifting into two gears.
    Push the gear selector forks as indicated.

  1. Using the special tool, remove the transaxle right-hand output drive flange.

  1. Using the special tool, remove the transaxle left-hand output drive flange.

  1. Using the special tool, remove the right-hand halfshaft oil seal.
    • Discard the oil seal.

  1. Using the special tools, remove the left-hand halfshaft oil seal.
    • Discard the oil seal.

  1. Remove the clutch housing retaining bolts.
    • Discard the bolts.

  1. NOTE:
    NOTE:Do not remove the two guide sleeves.
    Remove the transaxle housing retaining bolts.
    • Using two suitable tire levers, separate the two halves of the housing.
Vehicles built 01/2003 onwards
  1. Remove and discard the plug.
    • Carefully make a hole into the plug.
    • Pull out the plug using a screwdriver.

  1. Remove and discard the snap ring.
NOTE:
NOTE:Only carry out this step if the transaxle housing contains a M8 thread in the transaxle housing.
  1. Remove the transaxle housing using the special tool and a bolt M8x100 mm.
    • Heat the input shaft roller bearing area of the transaxle housing with a hot air gun to approx. 80°C.
NOTE:
NOTE:Only carry out this step if the transaxle housing does not contain a M8 thread in the transaxle housing.
  1. Using a suitable remover, clamp the input shaft.
NOTE:
NOTE:Only carry out this step if the transaxle housing does not contain a M8 thread in the transaxle housing.
  1. Remove the transaxle housing.
    • Heat the input shaft roller bearing area of the transaxle housing with a hot air gun to approx. 80°C.
  1. Remove the tool.
All vehicles
  1. Use a rubber band to support the differential.
Vehicles built up to 12/2002
  1. Remove the locking bolt.

  1. Remove the input shaft.

  1. Remove the output shaft, selector shaft and shift forks at the same time.

  1. Remove the reverse gear shaft.
    • Remove the reverse gear shaft thrust washer.

  1. Remove the 5th - 6th and reverse gear output shaft, 5th - 6th and reverse gear selector shaft and 5th - 6th and reverse gear shift forks at the same time.
Vehicles built 01/2003 onwards
  1. Remove the output shaft.
    1. Lift the 5th - 6th and reverse gear output shaft, reverse gear shaft, input shaft, 5th - 6th and reverse gear selector shaft and shift forks.
    1. Lift the output shaft to one side and remove.

  1. Remove the 5th - 6th and reverse gear output shaft together with the reverse gear shaft, input shaft, 5th - 6th and reverse gear selector shaft and shift forks.
    • Remove the reverse gear shaft thrust washer.
All vehicles
  1. Remove the differential.
    • Remove the magnet disc.
    • Remove the rubber band.

  1. NOTE:
    NOTE:Locate the internal extractor on the stabilizer ribs.
    Using an internal extractor, remove the selector shaft bearing bushings.
    1. Remove the fifth, sixth and reverse gear selector rod bearing bushing.
    1. Remove the first and second gear selector rod bearing bushing.
    1. Remove the third and fourth gear selector rod bearing bushing.

  1. Using an internal extractor, remove the reverse gear shaft bearing.
Vehicles built up to 12/2002
  1. Using an internal extractor, remove the input shaft bearing cup.
Vehicles built 01/2003 onwards
  1. NOTE:
    NOTE:Ensure that the snap ring stays pressed together during the removing of the input shaft parallel roller bearing to avoid damage.
    Using an internal extractor, remove the input shaft parallel roller bearing.
    1. Press the snap ring.
    1. Pull out the input shaft parallel roller bearing.
All vehicles
  1. NOTE:
    NOTE:Inspect the oil splash shield for damage.
    Using an internal extractor, remove the first to fourth gear output shaft bearing cup.

  1. Using an internal extractor, remove the fifth, sixth and reverse gear output shaft bearing cup.

  1. Using the special tool, remove the differential bearing cup.
    • Discard the oil splash shield.
Vehicles built up to 12/2002
  1. NOTE:
    NOTE:Remove the stop sleeves, only if they are damaged.
    Using the special tool, remove the stop sleeves.

  1. NOTE:
    NOTE:Remove the selector shaft locking pin, only if it is damaged.
    Using a suitable drift, remove the selector shaft locking pin.
All vehicles
  1. Using the special tool with an internal extractor, remove the selector shaft bearing bushings and the reverse gear shaft bearing.
    1. Remove the third and fourth gear selector rod bearing bushing.
    1. Remove the first and second gear selector rod bearing bushing.
    1. Remove the reverse gear shaft bearing.
    1. Remove the fifth, sixth and reverse gear selector rod bearing bushing.
Vehicles built up to 12/2002
  1. Using the special tool, remove the bearing cups with the adjustment shims.
Vehicles built 01/2003 onwards
  1. Using the special tool, remove the bearing cups with the adjustment shims.
All vehicles
  1. Using the special tool, remove the differential bearing cone.

Disassembly and Assembly of Subassemblies > < Transaxle - 1.9L Diesel