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Transit.Tourneo Connect 2002.5 (06.2002-)

Manual Transmission/Transaxle - Vehicles With: MTX-75/Manual Transaxle - Transaxle Transit/Tourneo Connect 2002.5 (06/2002-)
Assembly

Special Tool(s)

Remover/Installer, Front Hub Bearing Race

204-017 (14-010)

Installer, Front Hub Bearing Race/Oil Seal

204-050 (14-024)

Preload Gauge

205-067 (15-041)

Installer, Rear Hub Oil Seal

205-075 (15-036)

Installer, Drive Pinion Oil Seal

205-115 (15-058)

Socket, Drive Pinion Nut

205-175 (15-073)

Compressor, Valve Spring

303-060 (21-024)

Adapter for 303-060

303-060-02 (21-024-02)

Adapter for 303-060

303-060-07 (21-024-07)

Mounting Plate for 303-435-06

303-435-14A (21-212A)

Installer, Input Shaft Oil Seal

307-210 (17-041)

Holding Fixture, Dial Indicator Gauge (Output Shaft End Float)

308-194B (16-059B)

General Equipment
Press
Dial indicator gauge
Magnetic base for dial indicator gauge
Materials
Name
Specification
Transmission fluid
WSD-M2C200-C  
Sealant
WSK-M2G348-A5  
Sealer, slave cylinder
ESK-M4G269-A  
High-temperature grease
ESDM-1C220-A  

Assembly

All vehicles
  1. Clean and check all parts carefully before reassembly.

  1. NOTE:
    NOTE: Only if removed.
    Install the reverse gear idler shaft.
    1. Coat the mating surface of the reverse gear idler shaft with sealer.
    1. Position the reverse gear idler shaft with the locating bolt and drive it in.
    1. Unscrew the locating bolt and fit the original bolts.

  1. CAUTION:
    CAUTION: The press force must not exceed 15kN.
    Fit the bearing races on the transmission housing side.
    • Heat up the transmission housing locally to approximately 80°C using a hot air blower.
    • Cool the bearing races with temperature reduction spray and fit them.
    • Fit the bearing races using the press:

        • 1. Input shaft using 307-210 (17-041).

        2. Output shaft using 205-075 (15-036).

        3. Differential using 204-050 (14-024).

  1. Measuring shim to be fitted:
    • Input shaft: 1.00 mm.
    • Output shaft: 1.00 mm.
    • Differential: 1.10 mm.

  1. CAUTION:
    CAUTION: The press force must not exceed 15kN.
    Fit the measuring shims and the bearing races in the clutch-end housing section.
    • Heat up the transmission housing to approximately 80°C using a hot air blower.
    • Cool the bearing races with temperature reduction spray.
    1. Fit the measuring shims.
    1. Fit the bearing races.
    • Fit the bearing races using the press:

        • 1. Input shaft using 204-017 (14-010).

        2. Output shaft using 205-075 (15-036).

        3. Differential using 204-050 (14-024).

  1. NOTE:
    NOTE: Do not oil taper roller bearings which are to be used again. Install new taper roller bearings untreated.
    Fit the input shaft and the output shaft in the transmission housing.
    • Engage fourth gear.
    • Fit the input shaft and the output shaft together in the transmission housing.

  1. NOTE:
    NOTE: Do not oil taper roller bearings which are to be used again. Install new taper roller bearings untreated.
    Install the differential (illustration shows 1.8L diesel engine).

  1. NOTE:
    NOTE: Check that the mating surface is clean.
    Position the clutch-end housing section.
    • Attach the special tool to the transmission housing flange using the longer bolt.

  1. Install the clutch-end housing sections.
    • Tighten the 16 flange bolts uniformly.

  1. Install the special tool.
    • Position the measuring bar on the 4th gear wheel.

  1. Prepare the input shaft for measuring.
    • Turn the input shaft to and fro approximately 20 times to settle the bearings.

  1. Set up the dial indicator gauge.
    1. Attach the special tool to the transmission.
    1. Set up the magnetic dial indicator gauge base.
    1. Set the dial indicator to "0".

  1. NOTE:
    NOTE: Carry out both the previous and this step three times and calculate the average measurement.
    Measure the input shaft end float.
    1. Lift the input shaft with a lever.
    1. Note the resulting measurement (e.g. 0.22mm).
    • Example: 0.22 mm + 0.23 mm + 0.21 mm divided by three = 0.22 mm.

  1. Prepare the output shaft for measuring.
    • Turn the output shaft back and forth 20 times to settle the bearings (see previous step).
    • Set up the dial indicator gauge.
    • Set the dial indicator to "0".

  1. NOTE:
    NOTE: Carry out both this and the following step three times and calculate the average measurement.
    Measure the output shaft end float.
    • Lift the output shaft with a lever and note the resulting measurement, e.g. 0.32mm.
    • Example: 0.32 mm + 0.34 mm + 0.33 mm divided by three = 0.33mm.

  1. Prepare the differential for measuring.
    • Turn the input shaft backwards and forwards 20 times and at the same time press down the differential.
    • Set up the dial indicator and set it to "0".

  1. NOTE:
    NOTE: Carry out both this and the following step three times and calculate the average measurement.
    Measure the differential end float.
    • Lift the differential with the special tool and note the resulting measurement, e.g. 0.34mm.
    • Example: 0.34 mm + 0.36 mm + 0.38 mm divided by three = 0.36 mm.
  1. Calculate the required input shaft shim thickness.
    • Required shim thickness, 1.00 mm.
    • Measured end float (see previous step), 0.22 mm.
    • End float dimension = 0.05 mm.
    • Required shim: 0.22 mm - 0.05 mm + 1.00 mm = 1.17 mm.
  1. Calculate the required output shaft shim thickness.
    • Required shim thickness, 1.00 mm.
    • Measured end float (see previous step), 0.33 mm.
    • Preload dimension = 0.13 mm.
    • Required shim: 1.00 mm + 0.33 mm + 0.13 mm = 1.46 mm.
  1. Calculate the required differential shim thickness.
    • Required shim thickness, 1.10mm.
    • Measured end float (see previous step), 0.36 mm.
    • Preload dimension = 0.33 mm.
    • Required shim: 1.10 mm + 0.36 mm + 0.33 mm = 1.79 mm.
  1. Remove the bearing races again.
    • Fit the bearing races of the:

        • 1. Input shaft

        2. Output shaft

        3. Differential

  1. Fit the shims and bearing races.
    1. Fit the required shims.
    1. Fit the bearing races of the:

        2. 1. Input shaft

        2. Output shaft

        3. Differential

  1. Fit the reverse gear idler wheel.
    1. Lower thrust washer
    1. Needle roller bearing
    1. Reverse gear idler wheel (smaller collar faces downwards)
    1. Upper thrust washer
    1. Snap ring

  1. Install the input and output shafts together.

  1. Install selector fork.
    • Move the fourth gear selector ring to the neutral position.
    • Insert the fifth and reverse gear selector fork and swivel it to the side.

  1. Install the third and fourth gear selector fork.
    • Swivel back the fifth and reverse gear selector fork.

  1. NOTE:
    NOTE: When fitted correctly, the selector rods are the same height.
    Install the first and second gear selector fork and selector rods.

  1. Install the differential (illustration shows 1.8L diesel engine).
    1. Fit the differential.
    1. Place the clean magnetic disc in the recess.

  1. Coat the mating surface with sealant.
    • The mating surface must be dry and free of oil. Apply sealant evenly to the inside of the mating surface (even 2 mm bead of sealant).

  1. NOTE:
    NOTE: The transmission housing must not be turned over to tighten the bolts.
    Fit the clutch-end housing section.
    • Tighten the 16 flange bolts within 15minutes, working diagonally.

  1. NOTE:
    NOTE: Make sure the transmission is in neutral (the gearshift lever and selector lever must be vertical).
    Install the selector mechanism.
    • The mating surface must be dry and free of oil. Apply sealant evenly to the outside of the mating surface (even 2 mm bead of sealant).

  1. Measure the turning torque.
    • Engage fourth gear.
    • Measure the turning torque.
    • If the turning torque is too high, all the measurements (to establish the required shim thickness) must be repeated.
Vehicles with diesel engine

  1. Fit the speedometer drive pinion.
    • Insert the drive pinion.
    • Carefully drive in the roll pin.
All except vehicles with a diesel engine

  1. Install the vehicle speed sensor (VSS).
All vehicles

  1. Install the front driveshaft oil seals.

  1. WARNING:
    WARNING: Do not allow brake fluid to come into contact with the skin or eyes. If brake fluid contacts the skin or eyes, rinse the affected area immediately with water. Failure to observe this instruction can lead to injury.
    CAUTION:
    CAUTION: Wrap the input shaft splines with adhesive tape to protect the input shaft oil seal.
    CAUTION:
    CAUTION: Do not oil clutch slave cylinder.
    NOTE:
    NOTE: Install a new clutch slave cylinder.
    Install the clutch slave cylinder with a new oil seal and with slave cylinder sealer.
  1. Remove the adhesive tape from the input shaft splines.
  1. Apply a thin film of high-temperature grease to the input shaft splines.

Assembly|Installation > < Differential