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Differential > < Input Shaft

Focus 2004.75 (07.2004-)

Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75) - Output Shaft Focus 2004.75 (07/2004-)
Disassembly and Assembly of Subassemblies

Special Tool(s)

Installer, Drive Pinion Bearing

205-068 (15-042)

Remover, Bearing/Gear

205-310 (15-091)
General Equipment
Separating tool
Materials
Name
Specification
Transmission fluid
WSD-M2C200-C 

Disassembly
  1. Press off the transmission housing roller bearing together with the reverse gear gearwheel using the special tool.

  1. Remove the reverse gear synchronizer ring.
    1. Remove the needle roller bearing.
    1. Remove the synchronizer ring.

  1. NOTE:
    NOTE:If gear changes are difficult, carefully remove the synchronizer hub assembly and the fifth gear gearwheel
    Remove the fifth and reverse gear synchronizer hub assembly.
    1. Remove the snap-ring.
    1. Remove the synchronizer hub assembly.

  1. Remove the fifth gear gearwheel.
    1. Remove the synchronizer ring.
    1. Remove the fifth gear gearwheel.
    1. Remove the needle roller bearing.

  1. NOTE:
    NOTE:Use the special tool with the flat side upwards.
    Remove the fourth gear gearwheel using the special tool.
    • Remove the snap-ring.

  1. NOTE:
    NOTE:Do not use Special Tool 205-310.
    NOTE:
    NOTE:Use the separating tool with the flat side upwards.
    Remove the second and third gear gearwheel using a suitable separating tool.

  1. CAUTION:
    CAUTION:Be careful when handling the inner synchronizer ring and the synchronizer cone.
    Remove the second gear synchronizer rings.
    1. Remove the needle roller bearing.
    1. Remove the inner synchronizer ring.
    1. Remove the synchronizer cone.
    1. Remove the outer synchronizer ring.

  1. Remove the first and second gear synchronizer hub assembly.
    1. Remove the snap-ring.
    1. Remove the synchronizer hub assembly.

  1. CAUTION:
    CAUTION:Be careful when handling the inner synchronizer ring and the synchronizer cone.
    Remove the first gear gearwheel.
    1. Remove the outer synchronizer ring.
    1. Remove the synchronizer cone.
    1. Remove the inner synchronizer ring.
    1. Remove the first gear gearwheel.
    1. Remove the needle roller bearing.

  1. NOTE:
    NOTE:Only remove the bearing if it is to be renewed.
    Remove the transmission housing roller bearing using the special tool.

  1. CAUTION:
    CAUTION:Carefully remove the selector ring from the synchronizer hub assembly. The detent balls are spring-loaded.
    NOTE:
    NOTE:Mark the installed position of the selector ring.
    Disassemble the synchronizer hub assembly.
    1. Remove the selector ring.
    1. Remove the synchronizer body.
    1. Remove the compression springs.
    1. Remove the blocker bars.
    1. Remove the detent balls.

Assembly

  1. CAUTION:
    CAUTION:Be careful when handling the inner synchronizer ring and the synchronizer cone. Lubricate the synchronizer rings with transmission fluid prior to installation.
    NOTE:
    NOTE:Do not lubricate new roller bearings.
    Carefully clean and check all parts and lubricate sliding surfaces with transmission fluid prior to assembly.

  1. CAUTION:
    CAUTION:Be careful when handling the inner synchronizer ring and the synchronizer cone.
    Install the first gear gearwheel.
    1. Install the needle roller bearing.
    1. Install the first gear gearwheel.
    1. Install the inner synchronizer ring.
    1. Install the synchronizer cone.
    1. Install the outer synchronizer ring.

  1. NOTE:
    NOTE:Observe the markings.
    Assemble the synchronizer hub assembly.
    1. Install the compression springs.
    1. Install the blocker bar and the detent balls in the gear synchronizer hub against the force of the spring.
    1. Install the spring ring the correct way round and push it on.

  1. NOTE:
    NOTE:Install the synchronizer hub assembly with the wider collar facing outwards (towards the second gear gearwheel).
    Install the first and second gear synchronizer hub assembly.
    1. Install the synchronizer hub assembly.
    1. Install the snap-ring.

  1. Install the second gear gearwheel.
    1. Install the needle roller bearing.
    1. Install the outer synchronizer ring.
    1. Install the synchronizer cone.
    1. Install the inner synchronizer ring.
    1. Install the second gear gearwheel.

  1. Install the third gear gearwheel using the special tool.

  1. NOTE:
    NOTE:Install a new circlip.
    Install the fourth gear gearwheel using the special tool.

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

  1. NOTE:
    NOTE:Install the synchronizer hub assembly with the narrower collar and the annular groove facing outwards.
    Installation position of fifth and reverse gear synchronizer hub assembly.

  1. NOTE:
    NOTE:Install the synchronizer hub assembly with the narrower collar and the annular groove facing outwards.
    Install the fifth and reverse gear synchronizer hub assembly.
    1. Install the synchronizer hub assembly.
    1. Install a new snap ring.

  1. Install the reverse gear gearwheel.
    1. Install the synchronizer ring.
    1. Install the needle roller bearing.
    1. Install the reverse gear gearwheel.

  1. Install the transmission housing roller bearing using a suitable tube.

  1. Install the clutch housing roller bearing using a suitable tube.

Differential > < Input Shaft