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Disassembly and Assembly of Subassemblies > < Transmission

Transit 2000.5 (01.2000-05.2006)

Manual Transmission/Transaxle - Vehicles With: MT82 - Transmission Transit 2000.5 (01/2000-05/2006)

Disassembly

Special Tool(s)
205-047
Slide Hammer

205-071-01
Adapter for 205-071 (Thrust Pad)

205-072
Universal Flange Holding Wrench

205-078
Remover, Drive Pinion Seal

205-078-01
Adapter for 205-078 (Thrust Pad)

205-082
Installer, Differential Bearing

205-310
Remover, Bearing/Gear

205-329
Mounting Bracket, Engine/Differential

303-172-01
Adapter for 303-172

303-293
Remover, Crankshaft Seal

303-435
Mounting Stand

303-435-06
Mounting Bracket for 303-435

308-044
Installer, Transmission Extension Housing Bushing/Seal

308-150
Installer, Mainshaft Double Lip Seal
General Equipment
Hydraulic press
Puller
All vehicles
  1. Special Tool(s): 205-329, 303-435, 303-435-06

  1. WARNING:
    WARNING:Fluid may escape.
    Torque: 50 Nm

  1. Remove the following items:
    1. 4. Engage a gear.
    1. Special Tool(s): 205-072
    1. Detach the layshaft bolt.
    1. Detach the input shaft snap ring.

  1. Special Tool(s): 205-072

  1. Special Tool(s): 205-071-01
    General Equipment: Puller
Vehicles built from 09/2007
  1. NOTE:
    NOTE:This step is only required when installing a new component.
All vehicles
  1. Special Tool(s): 303-293

  1. Special Tool(s): 205-078, 205-078-01

  1. Special Tool(s): 205-047

  1. Special Tool(s): 303-172-01
    General Equipment: Puller

  1. Special Tool(s): 205-071-01
    General Equipment: Puller

  1.  
    1. Raise up the transmission shaft.
    1. Special Tool(s): 205-071-01
      General Equipment: Puller

  1. CAUTION:
    CAUTION:Make sure that no component falls off during removal.

  1. CAUTION:
    CAUTION:Take extra care not to scratch the support surface.
    Special Tool(s): 308-150
    General Equipment: Hydraulic press

  1. CAUTION:
    CAUTION:Take extra care not to scratch the support surface.
    General Equipment: Hydraulic press

  1. Special Tool(s): 308-044

  1. Special Tool(s): 308-044

  1. NOTE:
    NOTE:Make a note of/mark the installed positions of the components before removal.
    Remove the following items:
    1. Bolt, reverse gear mounting
    1. Reverse gear mounting
    1. Reverse gear

  1. Weld the special tool and suitable nuts to the domed steel washer.
    Special Tool(s): 205-047

  1. Synchronizer hub – 5th/6th gear
    Special Tool(s): 205-310
    General Equipment: Hydraulic press

  1. Gear wheel – 5th gear
    Special Tool(s): 205-310, 205-082
    General Equipment: Hydraulic press

  1. Gear wheel – 6th gear
    Special Tool(s): 205-310
    General Equipment: Hydraulic press

  1. Snap ring, synchronizer assembly - 3rd/4th gear

  1. Gear wheel - 4th gear and synchronizer assembly - 3rd/4th gear
    Special Tool(s): 205-310
    General Equipment: Hydraulic press

Disassembly and Assembly of Subassemblies > < Transmission