ford Workshop Repair Guides

Ford Transit Workshop Service and Auto Repair Manuals - Get Them Now

ABOUT US
Assembly|Installation > < Synchronizers

Transit 20005 Manual Transmission-Transaxle Clutch Removal & Assembly

Manual Transmission/Transaxle - Vehicles With: MT-75 - Transmission Transit 2000.5 (01/2000-05/2006)
Assembly

Special Tool(s)

Installer, Wear Sleeve Stub Axle

204-276 (14-055)

Adapter for 205-066

205-066-04 (15-068)

Flange Holding Wrench, Universal

205-072 (15-030A)

Installer, Differential Bearing Cone

205-074 (15-035)

Adapter for 205-074

205-074-01 (15-064)

Installer, Rear Hub Oil Seal

205-075 (15-036)

Aligner, Clutch Plate

303-173 (21-103A)

Angle Gauge, Bolt Tightening

303-174 (21-540)

Mounting Stand

303-435 (21-187)

Socket, Guide Sleeve

308-109 (16-040A)

Remover/Installer, Front Housing

308-110 (16-041)

Threaded Spindle

308-111 (16-042A-01)

Adapter for 308-111

308-111-01 (16-042A)

Installer, Output Drive Flange Oil Seal

308-112 (16-043A)

Mounting Bracket for 303-435

308-114 (16-045)

Mounting Brackets for 308-114

308-114-01 (16-045-01)
General Equipment
17 mm socket
Materials
Name
Specification
Manual transmission fluid
WSD-M2C200-C 
Sealant
WSS-M2G348-A10 
Sealant
ESK-M4G242-A 
Grease
ESD-M2C220-A 

Assembly

All vehicles
  1. NOTE:
    NOTE:Lubricate all moving parts with manual transmission fluid during assembly.
    NOTE:
    NOTE:Clean and check all parts for wear and damage. Install new parts as necessary.
    NOTE:
    NOTE:When installing a new transmission rear housing, install the locating studs with a 24 ± 0.5 mm protrusion.
    Using the special tools, install the output shaft bearing.

  1. Using the special tools, install the output shaft bearing.

  1. Install the output shaft bearing retaining bolts.

  1. Using the special tool, install the main selector shaft bearing.

  1. Using the special tool, install the countershaft rear bearing.
  1. Coat the lip of the main selector shaft oil seal with grease.

  1. Using a 17 mm socket, install the main selector shaft oil seal.

  1. NOTE:
    NOTE:Install new selector gate retaining bolts.
    Install the selector gate.

  1. NOTE:
    NOTE:Install a new input shaft bearing snap ring.
    Using the special tools, install the input shaft bearing.
    • Install the snap ring in the annular groove of the bearing.

  1. Using the special tool, install the countershaft front bearing.

  1. Using the special tool, install the main selector shaft bearing.

  1. Assemble the countershaft to the output shaft and secure it with a cable tie.

  1. NOTE:
    NOTE:The first and second gear selector fork must engage in the middle of the first and second gear synchronizer unit.
    Assemble the main selector shaft to the countershaft and output shaft assembly.

  1. NOTE:
    NOTE:Make sure that the flat end of the reverse gear idler shaft is facing upwards.
    Assemble the reverse gear idler to the countershaft and output shaft assembly and secure it with cable ties.

  1. NOTE:
    NOTE:Make sure that the outtrigger of the selector fork is facing upwards.
    Attach the fifth and reverse gear selector fork to the lower synchronizer unit.

  1. NOTE:
    NOTE:During installation, guide the main selector shaft into the bearing and selector gate correctly.
    NOTE:
    NOTE:Make sure that there is no touch condition between the countershaft and the synchronizer ring.
    NOTE:
    NOTE:Make sure that the inside splines of the sensor ring are facing to the output shaft flange.
    Using the special tools, install the countershaft and output shaft assembly.
    1. Install the vehicle speed sensor (VSS) ring.
    1. Use the special tools to guide the countershaft into the rear bearing.
  1. Remove the VSS ring.

  1. NOTE:
    NOTE:Do not fully tighten the reverse gear idler shaft rear retaining bolt at this stage.
    Install the reverse gear idler shaft rear retaining bolt.
  1. Remove the cable ties from the countershaft and output shaft assembly.

  1. Install the magnetic disc.

  1. NOTE:
    NOTE:Make sure that the chamfered end of the selector shaft is facing upwards.
    Install the third and fourth gear selector fork and the auxiliary selector shaft.

  1. CAUTION:
    CAUTION:Install the transmission front housing within 15 minutes of applying the sealant.
    Apply sealant to the mating surface of the transmission rear housing.

  1. CAUTION:
    CAUTION:Install the transmission front housing carefully. Failure to follow this instruction may result in damage to the fourth gear synchronizer ring.
    Assemble the transmission front housing to the transmission rear housing.

  1. NOTE:
    NOTE:During installation, guide the countershaft carefully into the bearing.
    Using the special tool, install the transmission front housing.

  1. NOTE:
    NOTE:Install a new input shaft circlip.
    Install the input shaft circlip.

  1. Install the transmission housing retaining bolts.

  1. CAUTION:
    CAUTION:Check the reversing lamp switch gasket. If the gasket is loose or damaged, discard the reversing lamp switch.
    NOTE:
    NOTE:Install new reversing lamp switch retaining bolts.
    Install the reversing lamp switch.

  1. Install the reverse gear idler shaft front retaining bolt
    • Tighten the reverse gear idler shaft retaining bolts.

  1. Install the selector shaft locking plate bolt.
  1. Apply sealant to the selector interlock mechanism retaining plug.

  1. Install the selector interlock mechanism.

  1. NOTE:
    NOTE:Make sure that the inside splines of the sensor ring are facing the output shaft flange.
    Install the VSS ring.
  1. Coat the lip of the output shaft oil seal with grease.

  1. Using the special tool, install the output shaft oil seal.
    • Install the splash shield.

  1. NOTE:
    NOTE:Vehicles built up to 10/2001 have a four bolt transmission output flange. Vehicles built 10/2001 onwards have a three bolt transmission output flange.
    Using the special tools, install the output shaft flange.
    • Hold the spindle with a drift.
  1. NOTE:
    NOTE:Install a new output shaft flange retaining nut.
    Coat the threads and the mating surface of the output shaft retaining nut with sealant.

  1. NOTE:
    NOTE:Vehicles built up to 10/2001 have a four bolt transmission output flange. Vehicles built 10/2001 onwards have a three bolt transmission output flange.
    Using the special tool, install the output shaft flange retaining nut.

  1. Using the special tool, install the input shaft guide sleeve oil seal.

  1. Assemble the input shaft guide sleeve.
    1. Install the thrust washer.
    1. Install the O-ring seal.
  1. Coat the threads of the input shaft guide sleeve and the O-ring seal with grease

  1. Using the special tool, install the input shaft guide sleeve.
  1. Coat the threads of the countershaft bearing retainer and the O-ring seal with grease.

  1. NOTE:
    NOTE:Install a new countershaft bearing retainer O-ring seal.
    Install the countershaft bearing retainer.

  1. Using the special tool, loosen the bearing retainer by 80 degrees.

  1. NOTE:
    NOTE:Rotate the transmission housing downwards at least 45 degrees.
    Adjust the countershaft.
    • Using a suitable brass drift and a soft faced hammer, strike two blows on each of the bosses. This will seat the countershaft front bearing against the bearing retainer.

  1. CAUTION:
    CAUTION:The indicated torque must be achieved.
    Using the special tool, tighten the bearing retainer 20 degrees.
    • If the indicated torque is not achieved, repeat the previous two steps.

  1. NOTE:
    NOTE:Install a new countershaft bearing retainer locking plate bolt.
    Install the countershaft bearing retainer locking plate.

  1. Install the clutch release bearing and the clutch release lever.

  1. NOTE:
    NOTE:Vehicles built up to 10/2001 have a four bolt transmission output flange. Vehicles built 10/2001 onwards have a three bolt transmission output flange.
    Remove the transmission from the mounting stand.

  1. NOTE:
    NOTE:Vehicles built up to 10/2001 have a four bolt transmission output flange. Vehicles built 10/2001 onwards have a three bolt transmission output flange.
    Install the drain plug.

  1. Install the gearshift lever connecting sleeve boot.

  1. Install the gearshift lever connecting sleeve.
Vehicles with tachograph
  1. Install the tachograph sensor.
All vehicles
  1. NOTE:
    NOTE:Install new gearshift lever support bracket retaining bolts.
    NOTE:
    NOTE:Do not fully tighten the gearshift lever support bracket retaining bolts at this stage.
    NOTE:
    NOTE:Vehicles built up to 10/2001 have a four bolt transmission output flange. Vehicles built 10/2001 onwards have a three bolt transmission output flange.
    Install the gearshift lever support bracket.
    1. Install the support bracket.
    1. Install the connecting sleeve boot to the support bracket.
  1. Tighten the gearshift lever support bracket retaining bolts.

  1. NOTE:
    NOTE:Vehicles built up to 10/2001 have a four bolt transmission output flange. Vehicles built 10/2001 onwards have a three bolt transmission output flange.
    Install the VSS.
  1. Fill the transmission with manual transmission fluid .

Assembly|Installation > < Synchronizers