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Focus 1999 (08.1998-12.2004)

Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (iB5) - Output Shaft Focus 1999 (08/1998-12/2004)
Disassembly and Assembly of Subassemblies

Special Tool(s)

Remover, Bearing (Main Tool)

205-295 (15-050A)

Installer, Extension Housing Bushing Oil Seal

308-045 (16-015)

Collet for 205-295

307-217 (17-048)
General Equipment
Two-leg puller
Press
Materials
Name
Specification
Transmission Oil
WSD-M2C200-C

Disassembly
  1. Remove the ball bearing and the fourth gear.
    1. Remove and discard the small snap ring.
    1. Install the output shaft snap ring .
    1. Using a suitable two-leg puller, remove the ball bearing.

        2. 1. Discard the output shaft snap ring and the ball bearing.

    1. Remove the fourth gear and the synchronizer ring.

  1. Remove the third and fourth gear synchronizer assembly.
    1. Remove and discard the snap ring.
    1. Remove the gear synchronizer, third and fourth gear synchronizer assembly and the third gear as an assembly.

  1. Third gear synchronizer assembly.
    1. Outer synchronizer ring.
    1. Synchronizer cone.
    1. Third gear.

  1. Remove the second gear synchronizer assembly
    1. Retaining ring.
    1. Snap rings.
    1. Second gear.
    1. Inner synchronizer ring.
    1. Synchronizer cone.
    1. Outer synchronizer ring.

  1. NOTE:
    NOTE:Remove the synchronizer assembly and the first gear as an assembly.
    Remove the first and reverse gear , the gear synchronizer and synchronizer assembly.
    1. Remove and discard the snap ring.
    1. Remove the first and second gear synchronizer clutch and the reverse gear .
    1. Outer synchronizer ring.
    1. Synchronizer cone.
    1. Inner synchronizer ring.
    1. First gear.

  1. CAUTION:
    CAUTION:To aid assembly mark the position of the selector ring in relation to the synchronizer hub.
    Disassemble the synchronizer clutch.
    1. Selector ring.
    1. Synchronizer spring.
    1. Synchronizer lock.
    1. Synchronizer hub.

  1. Using the special tools, remove the output shaft bearing cone.
    1. Remove and discard the output shaft bearing cone snap ring.
    1. Install the special tools underneath the bearing cone.

        2. 1. Discard the output shaft bearing cone.

Assembly

  1. Coat the synchronizer assembly with clean transmission oil before assembly.
  1. Carefully clean and check all running surfaces and coat them with clean transmission oil before assembly.

  1. NOTE:
    NOTE:Install a new output shaft bearing cone snap ring.
    NOTE:
    NOTE:Install a new output shaft bearing cone.
    Install the output shaft bearing cone.
    • Evenly heat the bearing cone to approximately 80°C and install it onto the output shaft.
    • Install the snap ring.

  1. NOTE:
    NOTE:Assemble the synchronizer clutch to the marks.
    Assemble the synchronizer clutch.
    1. Synchronizer hub.
    1. Selector ring.
    1. Synchronizer lock.
    1. Synchronizer spring.

  1. NOTE:
    NOTE:Use a new first and reverse gear snap ring.
    Install the first and reverse gear, the gear synchronizer and synchronizer assembly.
    1. First gear.
    1. Inner synchronizer ring.
    1. Synchronizer cone.
    1. Outer synchronizer ring.
    1. Install the first and second gear synchronizer clutch and the reverse gear.
    1. Install the snap ring.

  1. NOTE:
    NOTE:Assemble the synchronizer assembly before installation on the output shaft.
    Install the second gear synchronizer assembly.
    1. Outer synchronizer ring.
    1. Synchronizer cone.
    1. Inner synchronizer ring.
    1. Second gear.
    1. Snap rings.
    1. Retaining ring.

  1. Third gear synchronizer assembly.
    1. Third gear.
    1. Synchronizer cone.
    1. Outer synchronizer ring.

  1. NOTE:
    NOTE:Install a new third and fourth gear synchronizer assembly snap ring.
    NOTE:
    NOTE:Install the selector ring with the annular groove facing downwards and the small hub collar facing upwards.
    Install the third and fourth gear synchronizer assembly.
    1. Install the gear synchronizer, third and fourth gear synchronizer assembly and the third gear.
    1. Install the snap ring.

  1. NOTE:
    NOTE:Install a new snap ring.
    NOTE:
    NOTE:Install a new ball bearing.
    NOTE:
    NOTE:Install the ball bearing with the annular groove facing outwards.
    Using the special tool and a suitable press, install the fourth gear and the ball bearing.
    1. Install the synchronizer ring and the fourth gear.
    1. Using a suitable press , install the ball bearing.
    • Install the snap ring.

Differential > < Input Shaft