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Ford Workshop Service and Repair Manuals

308-03 Manual Transmission-Transaxle|Description and Operation > < Clutch Slave Cylinder - Vehicles Built From: 12-2003
Manual Transmission/Transaxle - Specifications Maverick 2005 (08/2004-)

General Specifications

Item Specification
Gear Clearance
1st gear end play 0.20-0.30 mm (0.0078-0.0118 in)
2nd gear end play 0.06-0.16 mm (0.0024-0.0063 in)
3rd gear thrust clearance 0.18-0.31 mm (0.0071-0.0122 in)
4th gear end play 0.20-0.30 mm (0.0078-0.0118 in)
5th gear thrust clearance 0.06-0.16 mm (0.0024-0.0063 in)
Synchronizer Ring Clearance
1st gear clearance (outer ring-to-synchronizer cone) 0.60-1.10 mm (0.0236-0.0433 in)
1st gear clearance (inner ring-to-synchronizer cone) 0.60-0.80 mm (0.0236-0.0314 in)
2nd gear clearance (middle synchronizer ring-to-gear) 0.60-1.20 mm (0.0236-0.0472 in)
2nd gear clearance (outer ring-to-synchronizer cone) 0.60-1.10 mm (0.0236-0.0433 in)
2nd gear clearance (inner ring-to-gear) 0.70-1.10 mm (0.0276-0.0433 in)
3rd gear 0.90-1.45 mm (0.0354-0.0571 in)
4th gear 0.90-1.45 mm (0.0354-0.0571 in)
5th gear 0.95-1.40 mm (0.0374-0.0551 in)
Reverse idler gear 0.95-1.40 mm (0.0374-0.0551 in)
Input Shaft
End play 0.00-0.06 mm (0.00-0.0024 in)
Adjustment shim thickness Refer to Transaxle in this section for shim selection procedure.
Mainshaft
End play 0.00-0.06 mm (0.00-0.0024 in)
Adjustment shim thickness Refer to Transaxle in this section for shim selection procedure.
Reverse Idler Gear
End play 0.04-0.14 mm (0.0016-0.0055 in)
Adjustment shim thickness Refer to Transaxle in this section for shim selection procedure.
Input shaft thrust washer thickness Refer to Input Shaft in this section for thrust washer thickness chart.
Input shaft snap ring thickness Refer to Input Shaft in this section for snap ring thickness chart.
4th gear adjustment shim thickness Refer to Mainshaft in this section for 4th gear adjustment shim thickness chart.
5th gear snap ring thickness Refer to Mainshaft in this section for 5th gear snap ring thickness chart.
Mainshaft C-ring thickness Refer to Mainshaft in this section for C-ring thickness chart.
Differential
Preload 0.15-0.21 mm (0.0059-0.0083 in)
Adjustment shim thickness Refer to Transaxle in this section for adjustment shim selection procedure.
Side gear and pinion gear backlash 0.02-0.08 mm (0.0079-0.0031 in)
Lubricants and sealants
SAE 75W-90 Long Life Gear Oil F32Z-19C547-MA WSS-M2C203-A1 and GL-4
Silicone Gasket and Sealant TA-30 WSE-M4G323-A4
Premium Long-Life Grease XG-1-C or XG-1-K (US); CXG-1-C (Canada) ESA-M1C75-B
High Performance DOT 3 Motor Vehicle Brake Fluid PM-1-C (US); CPM-1-C (Canada) WSS-M6C62-A

Torque Specifications

Description Nm lb-ft lb-in
Ball joint 63 46
Black transaxle case bolt 65 48
Clutch hydraulic line bracket bolt 2.5 22
Crossmember bolts 115 85
Drain plug 35 26
Fill level inspection plug 35 26
Final drive gear bolts 120 89
LH transaxle support insulator bolts 48 35
LH transaxle support insulator bracket nuts 40 30
LH transaxle support insulator through-bolt 103 76
Mainshaft bearing retainer bolt 7 62
Reduction gear bolts 96 71
Reverse lever bracket bolts 14 10
Shift assembly bolts 7 62
Shift cable bracket bolts 22 16
Shift check bolt 24 18
Stopper bolt 28 21
Stabilizer bar link 55 41
Standard (gold) transaxle case bolts 52 38
Tie-rod end 55 41
Transaxle fill plug 35 26
Transaxle front support insulator bolts 90 66
Transaxle front support insulator bracket bolts 48 35
Transaxle front support insulator through-bolt 115 85
Transaxle front-to-aft crossmember bolts 90 66
Transaxle front-to-aft crossmember nut 175 129
Transaxle rear support insulator bolt 80 59
Transaxle rear support insulator bracket bolts 48 35
Transaxle rear support insulator nuts 80 59
Transaxle rear support insulator through-bolt 115 85
Transaxle-to-engine bolts 47 35
Upper transaxle-to-engine bolts 45 33
Wiring harness bracket nuts 12 9

308-03 Manual Transmission-Transaxle|Description and Operation > < Clutch Slave Cylinder - Vehicles Built From: 12-2003