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Focus 2004.75 (07.2004-)

Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer Case > 308-03D Manual Transmission-Transaxle - Vehicles With: 6-Speed Manual Transmission (MMT6) > Description and Operation > Manual Transmission

Manual Transmission/Transaxle - Vehicles With: 6-Speed Manual Transmission (MMT6) - Manual Transmission Focus 2004.75 (07/2004-)
Description and Operation

Construction features on the differential side

 
Item
Part Number
Description
1
-
Differential
2
-
Reverse gear idler
3
-
1st gear wheel
4
-
1st/2nd gear synchronizer clutch
5
-
2nd gear wheel
6
-
3rd gear wheel
7
-
3rd/4th gear synchronizer clutch
8
-
4th gear wheel
9
-
Output shaft 1st/4th gear
10
-
Input shaft
11
-
Output shaft 5th/6th/reverse gear
12
-
6th gear wheel
13
-
5th/6th gear synchronizer clutch
14
-
5th gear wheel
15
-
Reverse gear synchronizer clutch
16
-
Reverse gear wheel
17
-
Output pinion – 5th/6th/reverse gear output shaft
18
-
Clutch housing

Construction features on the differential side

All gears have helical teeth and are permanently engaged.

5th, 6th and reverse gear have simple synchronisation. 1st to 4th gears are double synchronised.

Construction features on the input shaft side.

 
Item
Part Number
Description
1
-
Output shaft 5th/6th/reverse gear
2
-
Input shaft
3
-
Output shaft 1st/4th gear
4
-
3rd/4th gear synchronizer clutch selector fork
5
-
1st/2nd gear synchronizer clutch selector fork
6
-
Clutch housing
7
-
1st gear
8
-
2nd gear
9
-
5th gear
10
-
Reverse gear synchronizer clutch selector fork
11
-
3rd gear
12
-
5th/6th gear synchronizer clutch selector fork
13
-
4th/6th gear gearwheel

All driving gear wheels of the transmission are located on the input shaft.

The input shaft is a solid shaft and runs on one ball bearing and one roller bearing.

Because of this mounting the input shafts runs without preload and therefore needs no adjusting shims.

The input shaft seal nearest the clutch is pressed into the clutch housing.

Input shaft

 
Item
Part Number
Description
1
-
Clutch housing roller bearing
2
-
1st gear
3
-
2nd gear
4
-
5th gear
5
-
3rd gear
6
-
Input shaft ball bearing holder
7
-
Bearing retaining bolt
8
-
4th/6th gear wheel

Input shaft

The gear wheels for 1st and 2nd gear are an integral part of the input shaft. The gearwheels for 3rd and 5th gears and the gearwheel for 4th/6th gear are pressed on.

Because of the high force used to press on the components, the gear wheels cannot be pressed off in service. A faulty input shaft can only be replaced as a complete unit.

Defective bearings can be pressed off and changed.

Output shaft 1st/4th gear

The 1st/4th gear output shaft runs on tapered roller bearings.

This bearing arrangement requires the shaft to be preloaded. Please refer to the service literature for further information on how to measure the pre-load.

The output pinion of the 1st/4th gear output shaft is an integral part of the shaft.

The synchroniser assemblies of the 1st/2nd and the 3rd/4th gears are located on the output shaft.

The 1st to 4th gear output shaft is a hollow shaft; the oil is supplied to the internal oilways via oil funnels.

Internal oilways provide lubrication to the needle roller bearings and the synchroniser assemblies.

 
Item
Part Number
Description
1
-
Transmission housing taper roller bearing
2
-
4th gear wheel
3
-
Needle bearing
4
-
Inner synchroniser ring
5
-
4th gear synchronizer cone
6
-
Outer synchronizer ring (4th gear)
7
-
Snap ring
8
-
3rd/4th gear synchronizer
9
-
Outer synchronizer ring (3rd gear)
10
-
3rd gear synchronizer cone
11
-
Inner synchroniser ring
12
-
3rd gear wheel
13
-
Needle bearing
14
-
Stop disc unit
15
-
2nd gear wheel
16
-
Needle bearing
17
-
Inner synchroniser ring
18
-
2nd gear synchronizer cone
19
-
Outer synchronizer ring (2nd gear)
20
-
Snap ring
21
-
1st/2nd gear synchronizer
22
-
Outer synchronizer ring (1st gear)
23
-
1st gear synchronizer cone
24
-
Inner synchroniser ring
25
-
1st gear wheel
26
-
Needle bearing
27
-
Output shaft 1st/4th gear
28
-
Oil storage ring (until 10/2005)
29
-
Clutch housing taper roller bearing
30
-
Bearing retaining bolt (left-hand thread)

Output shaft 5th/6th/reverse gear

The 5th/6th/reverse gear output shaft runs on tapered roller bearings.

This bearing arrangement requires the shaft to be preloaded. Please refer to the service literature for further information on how to measure the pre-load.

The output pinion is an integral part of the shaft.

The 5th/6th and reverse gear synchronizer assemblies are located on the shaft.

The 5th/6th/reverse gear output shaft is a hollow shaft; the oil is supplied to the internal oilways via oil funnels.

Internal oil passages provide lubrication to the needle roller bearings and the synchronizer assemblies.

 
Item
Part Number
Description
1
-
Transmission housing taper roller bearing
2
-
Needle bearing
3
-
6th gear wheel
4
-
6th gear synchronizer ring
5
-
Snap ring
6
-
5th/6th gear synchronizer
7
-
Synchronizer ring (5th gear)
8
-
Stop disc unit
9
-
Needle bearing
10
-
5th gear wheel
11
-
Snap ring
12
-
Oil storage ring (until 10/2005)
13
-
Clutch housing taper roller bearing
14
-
Output shaft 5th/6th/reverse gear
15
-
Reverse gear wheel
16
-
Needle bearing
17
-
Reverse gear synchronizer ring
18
-
Reverse gear synchronizer
19
-
Bearing retaining bolt (left-hand thread)

Oil funnel and oil storage ring

Until 10/2005 an oil storage ring was installed on the clutch side in each of the two output shafts.

 
Item
Part Number
Description
1
-
Oil funnel until 10/2005
2
-
Oil storage ring until 10/2005
3
-
Oil funnel from 11/2005

When installing a new oil funnel, from 11/2005 onwards, an oil storage ring is no longer permitted, as this could lead to a loss of transmission fluid pressure in the output shaft and therefore to a loss of lubrication.

Synchroniser assembly

 
Item
Part Number
Description
1
-
Sliding block assembly
2
-
Synchroniser hub
3
-
Sliding collar

The (MMT6) synchroniser assemblies have been reworked for the 6-speed manual transmission.

The detent balls, springs and sliding blocks form one unit.

This arrangement makes it easier to service the synchroniser assembly.

Differential

Because the Vehicle Speed Sensor (VSS) is discontinued, so is the sender wheel.

The ABS wheel speed sensors send the current wheel speed to the powertrain control module (PCM).

The differential has taper roller bearings.

This bearing arrangement requires the shaft to be preloaded. Please refer to the service literature for further information on how to measure the pre-load.

 
Item
Part Number
Description
1
-
Transmission housing taper roller bearing
2
-
Differential
3
-
Clutch housing taper roller bearing
4
-
Crown wheel bolts
5
-
Crown wheel

Power transmission in the individual gears

The following diagrams show a schematic representation of the power flow.

Power is transmitted via the non-positive gear pair to the output pinion of the output shaft(s) and thus to the differential ring gear.

NOTE:
NOTE:The three shafts are shown away from their real positions for clarity.

Power transmission route in 1st gear

The 1st gear wheel is positively connected to the 1st to 4th gear output shaft by the 1st/2nd gear synchroniser assembly.

Power transmission route in second gear

The 2nd gear wheel is positively connected to the 1st to 4th gear output shaft by the 1st/2nd gear synchroniser assembly.

Power transmission route in 3rd gear

The 3rd gear wheel is positively connected to the 1st to 4th gear output shaft by the 3rd/4th gear synchroniser assembly.

Power transmission route in 4th gear

The 4th gear wheel is positively connected to the 1st to 4th gear output shaft by the 3rd/4th gear synchroniser assembly.

Power transmission route in 5th gear

The 5th gear wheel is positively connected to the 5th/6th/reverse gear output shaft by the 5th/6th gear synchroniser assembly.

Power transmission route in 6th gear

The gear wheel of the 4th/6th gear drives not only the gear wheel of the 4th gear but also of the 6th gear.

The 6th gear wheel is positively connected to the 5th/6th/reverse gear output shaft by the 5th/6th gear synchroniser assembly.

Power transmission route in reverse gear

The reverse gear idler is welded to the 1st gear wheel. It is constantly engaged with the reverse gear wheel (shown separated for clarity).

The reverse gear wheel is positively connected to the 5th/6th/reverse gear output shaft by the reverse gear synchroniser assembly.

Internal shift mechanism

 
Item
Part Number
Description
1
-
Counterbalance
2
-
Reverse gear switch
3
-
Selector shaft
4
-
Selector gate

Internal shift mechanism

The internal shift mechanism has been newly developed for this transmission.

The reverse gear switch is located on the housing cover of the internal shift mechanism.

The counterbalance improves the smoothness of the gear shifting. Due to its mass, the synchronization shift resistances that can be felt during shifting are reduced. The gear shifting process becomes smoother.

The internal shift mechanism can only be changed as a complete unit in service.

Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer Case > 308-03D Manual Transmission-Transaxle - Vehicles With: 6-Speed Manual Transmission (MMT6) > Description and Operation > Manual Transmission

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