ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

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Reverse Idler Gear > < Countershaft

Transit 2006.5 (04.2006-)

Manual Transmission/Transaxle - Vehicles With: MT-75 - Output Shaft Transit 2006.5 (04/2006-)
Disassembly and Assembly of Subassemblies

Special Tool(s)

Remover, Mainshaft Needle Bearing Sleeve

308 - 191 (16 - 056)
General Equipment
Hot air gun
Materials
Name
Specification
Manual transmission fluid
WSD - M2C200 - C 

Disassembly
  1. CAUTION:
    CAUTION:Mark the position of the synchronizer rings in relation to the synchronizer units to aid installation.
    Remove the input shaft and fourth gear synchronizer ring from the output shaft.
    • Remove the output shaft locating bearing.

  1. Remove the fifth gear wheel and synchronizer ring from the output shaft.
    1. Remove the gear wheel.
    1. Remove the gear synchronizer ring.
    1. Remove the needle roller bearing.

  1. WARNING:
    WARNING:Do not allow the synchronizers to fall apart. Failure to follow these instructions may result in personal injury.
    CAUTION:
    CAUTION:Use soft jaws for all operations in a vise.
    NOTE:
    NOTE:Clamp the output shaft in a vise with the output end.
    Remove the third/fourth gear synchronizer unit together with the third gear wheel.
    1. Remove the circlip.
    1. Third/fourth gear synchronizer.
    1. Needle roller bearing.
    1. Third gear wheel.

  1. Using the special tool, remove the third gear bearing ring.
    • Locate the special tool in the recesses off the bearing ring.

  1. NOTE:
    NOTE:Mark the position of the second gear wheel in relation to the synchronizer ring to aid installation.
    Remove the second gear wheel, the needle roller bearing and synchronizer ring.

  1. NOTE:
    NOTE:Mark the position of the shift ring in relation to the first gear wheel to aid installation.. Components are paired.
    NOTE:
    NOTE:Remove the circlip.
    Remove the first/second gear synchronizer and the first gear wheel.
    1. First/second gear synchronizer.
    1. First gear wheel.
    1. Needle roller bearing.

  1. NOTE:
    NOTE:Mark the position of the shift ring in relation to the reverse gear wheel to aid installation. Components are paired.
    NOTE:
    NOTE:Clamp the output shaft the other way round in the vise.
    NOTE:
    NOTE:Remove the circlip.
    Remove the fifth/reverse gear synchronizer, the reverse gear wheel and needle roller bearing.
    1. Fifth/reverse gear synchronizer.
    1. Reverse gear wheel.
    1. Needle roller bearing.

Assembly

  1. Carefully clean and check all sliding parts and lubricate the synchronizer rings with Manual transmission fluid before assembly.

  1. Install the needle roller bearing, reverse gear wheel and synchronizer unit.
    1. Install the reverse gear wheel.
    1. Install the synchronizer.
    1. Install the snap ring.

  1. Install the first/second gear synchronizer unit.
    1. Install the needle roller bearing.
    1. Install the gear wheel.
    1. Install the synchronizer unit.
    • Install the circlip.

  1. Install the synchronizer ring, needle roller bearing and second gear wheel.
    1. Install the needle roller bearing.
    1. Install the synchronizer ring.
    1. Install the gear wheel.

  1. NOTE:
    NOTE:Slide the inner bearing ring onto the output shaft as far as the shoulder.
    NOTE:
    NOTE:Install a new inner bearing ring and needle bearing.
    Using a hot air gun heat the inner bearing ring to approximately 100 ° C and install it.

  1. NOTE:
    NOTE:Install the synchronizer with the small collar upwards.
    NOTE:
    NOTE:Install the needle roller bearing.
    Install the third/fourth gear synchronizer.
    1. Install the gear wheel.
    1. Install the synchronizer.
    1. Install the circlip.

  1. Install the fifth gear wheel.
    1. Install the needle roller bearing.
    1. Install the synchronizer ring.
    1. Install the gear wheel.

  1. Install the output shaft locating bearing, synchronizer ring and the input shaft.

Reverse Idler Gear > < Countershaft