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

Mondeo 1997 (08.1996-09.2000)

Manual Transmission/Transaxle - Output Shaft—Vehicles Built Up To: 08/2000 Mondeo 1997 (08/1996-09/2000)
Disassembly and Assembly of Subassemblies

Special Tool(s)

Remover, taper roller bearing (basic tool)

205-295 (15050A)

Collet for 205-295

308-197 (16062)
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. NOTE:
    NOTE:The taper roller bearing and the reverse gear wheel can also be pressed off together.
    Pull off the taper roller bearing on the transmission housing side.

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

  1. NOTE:
    NOTE:If gear changes are difficult, carefully prise off the synchronizer assembly with the 5th gear wheel.
    Remove the complete 5th/reverse gear synchronizer assembly.
    1. Snap-ring
    1. Synchronizer assembly, complete

  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. Pull off the taper roller bearing on the clutch side.

  1. CAUTION:
    CAUTION:The output shaft and output pinion are paired and must only be renewed together.
    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 together with the needle roller bearing.
    1. Needle roller bearing
    1. Inner synchronizer ring
    1. Synchronizer cone
    1. Outer synchronizer ring

  1. NOTE:
    NOTE:If gear changes are difficult, carefully prise off the synchronizer assembly with the 5th gear wheel.
    Remove the 1st/2nd gear synchronizer assembly.
    1. Snap-ring
    1. Synchronizer assembly, complete

  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 off the synchronizer hub. The detent balls are spring loaded.
    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. CAUTION:
    CAUTION:Immerse the double synchronizers in transmission fluid prior to installation.
    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:Marking.
    Assemble the 1st/2nd gear synchronizer.
    1. Insert the compression springs.
    1. Insert the locker bar with the detent balls against the force of the spring.
    1. Fit 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.
    Installation position of 1st/2nd gear synchronizer assembly

  1. NOTE:
    NOTE:Attach the synchronizer hub with the small collar and the annular groove facing outwards.
    Fit the complete 1st/2nd gear synchronizer assembly.
    1. Synchronizer assembly.
    1. Fit a new snap-ring.

  1. NOTE:
    NOTE:See step
    Attach the 1st gear wheel with the double synchronizer.
    1. Outer synchronizer ring
    1. Synchronizer cone
    1. Inner synchronizer ring
    1. Gear wheel (1st gear)
    1. Needle roller bearing

  1. CAUTION:
    CAUTION:There is only one way to fit the output pinion onto the teeth.
    Press the output pinion on.
    • Install the output pinion with the mark pointing upwards.
    1. Press on the output pinion using a suitable length of tube and a press .
    1. Fit a new snap-ring.

  1. Press the taper roller bearing on at the clutch end.
    • Press on the taper roller bearing using 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. Assemble the 5th/reverse gear synchronizer.
    1. Insert the compression springs.
    1. Insert the locker bar with the detent balls against the force of the spring.
    1. Fit the selector ring the right way round and slide it on.

  1. NOTE:
    NOTE:Fit the synchronizer hub with the small collar and the ring groove facing outwards.
    Installation position of 5th/reverse gear synchronizer assembly

  1. NOTE:
    NOTE:Fit the synchronizer hub with the small collar and the ring groove facing outwards.
    Attach the 5th/reverse gear synchronizer assembly as a unit.
    1. Synchronizer assembly.
    1. Fit 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 on the transmission housing side.
    • Press on the taper roller bearing using a suitable length of tube and a press .

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