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Assembly|Installation > < Transaxle - Vehicles Built Up To: 07-2000

Fiesta 1996 (08.1995-02.2002)

Manual Transmission/Transaxle - Transaxle—Vehicles Built From: 07/2000 Fiesta 1996 (08/1995-02/2002)
Assembly

Special Tool(s)

Installer, Rear Hub Bearing Cone/Oil Seal

205-296 (15-085)

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 Stand

303-435 (21-187)

Installer, Halfshaft Oil Seal

308-039 (16-018)

Installer, Input Shaft Bearing Cone

308-041 (16-020)

Installer, Extension Housing Bushing Oil Seal

308-045 (16-015)

Installer, Input Shaft Snap Ring

308-076 (16-031)
General Equipment
Press
Dial indicator gauge
Magnetic base for dial indicator gauge
Auxiliary plug
M8 x 50 mm bolt
Center punch
Tap
Materials
Name
Specification
Universal sealer
ESEE-M4G1008-A 
Silicon sealer
WSE-M4G323-A4 
Sealer
WSK-M2G348-A5 
Transmission fluid
WSD-M2C200-C 
High-temperature grease
ESDM-1C220-A 

Assembly

  1. Clean and check all parts carefully before reassembly.

  1. Install the output shaft roller bearing and the bearing outer race with the special tool.
    1. Install the oil thrower.
    1. Install the output shaft roller bearing.

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

  1. Install the differential assembly and permanent magnet.

  1. Install the reverse gear idler.

  1. Install the selector shaft with the shift locking plate.

  1. Prepare input and output shaft for installation.
    1. Engage the input shaft and output shaft.
    1. Position the 1st/2nd gear selector fork.
    1. Position the 3rd/4th gear selector fork.

  1. NOTE:
    NOTE:Attach a rubber band to the selector shaft as an aid to assembly.
    Install the input and output shafts.
    • Insert the input shaft to a depth of approx. 50 mm and move slightly to one side.
    • Insert the output shaft level with the input shaft and engage the gear wheels again.
    • Install the input and output shafts.

  1. NOTE:
    NOTE:Replace the lower snap ring.
    Install the selector shaft guide sleeve and lower snap ring.
    1. Install the selector shaft guide sleeve.
    1. Install the lower snap ring.

  1. NOTE:
    NOTE:Replace the upper snap ring.
    Attach the upper snap ring for the selector shaft guide sleeve.
    1. Lift the guide sleeve.
    1. Install the upper snap ring.

  1. Switch the inner gearshift linkage to 5th gear.
    • Turn the auxiliary selector shaft clockwise until the reverse gear/5th gear shift gate is reached, then press downwards.

  1. Install a 3.8 mm measuring shim and secure using a center punch.
    1. Transmission housing
    1. Measuring shim
    1. Bearing outer race

  1. NOTE:
    NOTE:Thoroughly clean the transmission housing mating faces.
    Assemble the transmission housing.
    • Insert the auxiliary plugs.
    • Tighten the bolts.
    • Turn the transmission through 180 degrees.

  1. Attach the special tools.
    • Remove the auxiliary plugs.

  1. Prepare the differential for measuring.
    • Turn the differential approx. ten times to settle the bearings.

  1. NOTE:
    NOTE:Carry out the measurement three times and calculate the average value.
    NOTE:
    NOTE:The adjusting shims are available from 0.1 mm to 1.1 mm in steps of 0.1 mm.
    Measure the differential end float.
    1. Raise the differential assembly using the special tool.
    1. Note the resulting measurement (e.g. 0.73 mm).
    • Example: 0.73 mm + 0.74 mm + 0.72 mm divided by three = 0.73 mm.

        • 1. The thickness of the adjusting shims must be rounded down to the nearest tenth of a millimeter if the attained value is 0.05 mm or less and rounded up if the attained value is 0.06 mm or more.
  1. Calculate the required adjustment shim thickness.
    • Adjustment shim thickness = measuring shim (3.80 mm) + average value (0.73 mm) + bearing preload (0.40 mm) - thickness of Belleville washers (4.42 mm)

        • 1. Example: Adjusting shim = 3.80 mm + 0.73 mm + 0.40 mm - 4.42 mm = 0.51 mm.

    • The adjusting shim thickness is 0.5 mm (rounded off to 0.51 mm)

  1. Separate the transmission housing sections.
    • Detach the dial indicator gauge with the magnetic base and the special tools.
    • Insert the auxiliary plugs.
    • Turn the transmission through 180 degrees.

  1. Using the special tool, remove the differential bearing outer race and the measuring shim.

  1. NOTE:
    NOTE:The inner diameters of the Belleville washers contact one another.
    Install the adjusting shim determined and secure with a blow from a punch.
    1. Install the Belleville washers.
    1. Install adjusting shim of determined thickness.
    1. Install the bearing race.

  1. Evenly coat the inner edge of the transmission housing mating face with sealer

  1. Assemble the transmission housing and tighten the bolts evenly.

  1. NOTE:
    NOTE:Replace the snap rings for the input and output shafts.
    Carefully lift the input and output shafts and install the snap rings.
  1. Clean all threaded holes using a suitable tap.

  1. NOTE:
    NOTE:Replace the 5th gear housing gasket.
    Install the 5th gear housing gasket.

  1. Position the input and output shaft snap rings as shown.

  1. NOTE:
    NOTE:Replace the 5th gear housing bolts.
    Attach the 5th gear housing.
  1. Detach the transmission from the assembly stand.

  1. NOTE:
    NOTE:The transmission housing must not sit on the press table. Support the assembly on the splined clutch input shaft on the press table.
    Install the 5th gear wheel using the special tool and a suitable press.
  1. Mount the transmission on the mounting stand.

  1. NOTE:
    NOTE:Replace the snap ring for the 5th gear wheel.
    Using the special tool, install the 5th gear wheel snap ring.

  1. NOTE:
    NOTE:Only install in neutral position.
    Installation position for secondary selector shaft interlock.

  1. NOTE:
    NOTE:Only install in neutral position.
    Install the auxiliary selector shaft interlock.

  1. NOTE:
    NOTE:Identification of gear synchronizer installation position.
    Assemble the 5th gear synchronizer unit.
    1. 5th gear wheel
    1. Synchronizer ring
    1. Gear synchronizer
    1. Retaining plate

  1. NOTE:
    NOTE:Replace the snap ring for the 5th gear synchronizer unit.
    NOTE:
    NOTE:Replace the selector fork retaining pin
    Install the 5th gear synchronizer unit and selector fork.
    • Install the selector fork retaining pin.
    • Install the snap ring for the 5th gear synchronizer unit.

  1. Evenly apply sealer on the inside of the 5th gear housing mating face.

  1. Attach the 5th gear housing end cover.

  1. Install both front drive halfshaft oil seals using the special tool (left-hand side shown).

  1. Install the vehicle speed sensor (VSS).
    1. Install the VSS.
    1. Install the retaining pin.

  1. CAUTION:
    CAUTION:Wrap the input shaft splines with adhesive tape to protect the input shaft oil seal.
    Position the input shaft oil seal.

  1. CAUTION:
    CAUTION:Do not coat the clutch slave cylinder with high-temperature grease.
    Fit the clutch slave cylinder.
    • Tighten the bolts evenly, pressing the input shaft oil seal into the transmission housing.
  1. Remove the adhesive tape from the input shaft splines.
  1. Coat the input shaft splines lightly with grease.
  1. Remove the transmission from the mounting stand.

Assembly|Installation > < Transaxle - Vehicles Built Up To: 07-2000