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Disassembly and Assembly of Subassemblies > < Transaxle - 1.8L Duratorq-TDCi (Lynx) Diesel

C-MAX 2003.75 (06.2003-)

Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75) - Transaxle C-MAX 2003.75 (06/2003-)
Disassembly

Special Tool(s)

Remover, Drive Pinion Oil Seal

205-078

Adapter for 205-078

205-078-01

Remover, Differential Bearing Outer Race

205-176

Mounting Bracket, Engine/Differential

205-329

Mounting Stand

303-435

Mounting Bracket for 303-435

303-435-06

Remover, Halfshaft Oil Seal

308-208
General Equipment
Two tire levers
Hardwood drift

Disassembly
  1. CAUTION:
    CAUTION:All bearings are paired and must not be mixed.
    Mount the transmission on the assembly stand using the special tool.

  1. Remove the gearshift cable abutment.

  1. NOTE:
    NOTE:Ensure that the selector mechanism is in the neutral position.
    Remove the selector mechanism.

  1. Remove the input halfshaft seal on both sides using the special tool and discard (left-hand side shown).
  1. CAUTION:
    CAUTION:Use adhesive tape to cover the halfshaft splines to prevent damage to the halfshaft seal.
    Degrease the input shaft splines.

  1. CAUTION:
    CAUTION:Only remove the clutch slave cylinder / release bearing assembly if it is damaged or leaking.
    Remove the clutch slave cylinder / release bearing assembly.
    • Detach the boot.
    • Discard the clutch slave cylinder bolts.

  1. Remove the transmission housing bolts.

  1. CAUTION:
    CAUTION:Do not drive out the transmission housing locating dowels.
    Separate the clutch housing from the transmission housing using two tire levers.
  1. Remove the adhesive tape from the input shaft splines.

  1. NOTE:
    NOTE:Tilt the differential slightly.
    Remove the differential assembly.
    • Remove the magnetic disc.

  1. Remove the bolts from the reverse gear idler shaft mounting.

  1. Remove the selector rods.

  1. Remove the selector forks.
    1. Remove the 1st/2nd gear selector fork.
    1. Remove the 3rd/4th gear selector fork.
    1. Remove the 5th/reverse gear selector fork.

  1. Remove the reverse gear idler shaft mounting.
    • Turn the input shaft and output shaft to the side in order to move the reverse gear idler shaft mounting upwards.
    • The reverse gear idler remains in the transmission housing.

  1. Remove the input shaft together with the output shaft.

  1. Remove the reverse gear idler.
    • Remove the needle roller bearing and thrust washers.

  1. Remove the differential bearing outer race using the special tool.

  1. Remove the input shaft and output shaft bearing outer races using the special tool.

  1. Remove the input shaft bearing outer race and adjusting shim and the differential bearing outer race and adjusting shim using the special tool.

  1. Remove the output shaft bearing outer race and adjusting shim using the special tool.

  1. CAUTION:
    CAUTION:Only remove the reverse gear idler shaft if it is damaged.
    Remove and discard the reverse gear idler shaft retaining bolts.

  1. Remove the reverse gear idler shaft using a suitable hardwood drift.

Disassembly and Assembly of Subassemblies > < Transaxle - 1.8L Duratorq-TDCi (Lynx) Diesel