ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

ABOUT US
Differential > < Output Shaft

Galaxy 2000.75 (04.2000-02.2006)

Manual Transmission/Transaxle - Vehicles With: 6-Speed Manual Transmission (MT350) - 5th-6th and Reverse Gear Output Shaft Galaxy 2000.75 (04/2000-02/2006)
Disassembly and Assembly of Subassemblies

Special Tool(s)

Remover/Installer, Lower Arm Bushing

204-058 (14-027)

Installer, Drive Pinion Bearing

205–068 (15–042)

Adapter for 205-071 (Thrust Pad)

205-071-01 (15-026A-01)

Installer, Drive Pinion Oil Seal

205-077 (15-047A)

Remover, Bearing (Main Tool)

205-295 (15-050A)

Remover, Bearing/Gear

205-310 (15-091)

Socket, Bearing Retainer

307-325 (17-072)

Collet for 205-295

308-196 (16-061)

Collet for 205-295

308-197 (16-062)
Materials
Name
Specification
Manual transmission fluid
N052146VX00 

Disassembly

NOTE:
NOTE:Using a suitable press, remove the gear wheels.
NOTE:
NOTE:Use vise jaws protectors for all operations in a vise.
  1. Clamp the output shaft in a vise.

  1. Using the special tools, remove the transaxle housing roller bearing.
    1. Remove the snap ring.
    1. Install the special tools.
    • Discard the snap ring.

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

  1. Using the special tool, remove the fifth and sixth gear synchronizer and the sixth gear wheel.
    1. Remove the snap ring.
    1. Remove the synchronizer and the gear wheel.
    • Discard the snap ring.

  1. NOTE:
    NOTE:Mark the position of the selector ring in relation to the synchronizer hub to aid installation. Components are paired.
    Disassemble the fifth and sixth gear synchronizer.
    1. Remove the selector ring.
    1. Remove the synchronizer springs.
    1. Remove the blocker bars.
    1. Remove the gear synchronizer hub.

  1. Remove the needle roller bearing and snap ring.
    • Discard the snap ring.

  1. Using the special tool, remove the reverse gear wheel and the spacer sleeve.

  1. Remove the needle roller bearing and snap ring.
    1. Remove the needle roller bearing.
    1. Remove the snap ring.
    • Discard the snap ring.

  1. Remove the reverse gear synchronizer.

  1. Using the special tools, remove the clutch housing roller bearing.

Assembly

WARNING:
WARNING:When installing the bearing cones and gear wheels, heat them to approximately 100 ° C before assembly. Use a thick cloth to prevent the possibility of scalding. Failure to follow this instruction may result in personal injury.
NOTE:
NOTE:Using a suitable press, install the gear wheels and roller bearings.
NOTE:
NOTE:Use vise jaws protectors for all operations in a vise.
NOTE:
NOTE:When installing new roller bearings, do not lubricate the bearings.
NOTE:
NOTE:Lubricate the synchronizer rings with manual transmission fluid before assembly.
  1. Carefully clean and check all sliding parts and lubricate them with manual transmission fluid before assembly.

  1. Using the special tool, install the clutch housing roller bearing.

  1. NOTE:
    NOTE:The large collar of the reverse gear synchronizer hub must be facing towards the toothed ring of the output shaft.
    Using a suitable length of tube, install the reverse gear synchronizer hub.

  1. NOTE:
    NOTE:Install a new snap ring.
    Install the reverse gear selector ring.
    1. Install the snap ring.
    1. Install the needle roller bearing.
    1. Install the selector ring.

  1. NOTE:
    NOTE:The large collar of the spacer sleeve must be facing towards the reverse gear wheel.
    Using the special tool, install the reverse gear wheel and the spacer sleeve.
    1. Install the reverse gear wheel.
    1. Install the spacer sleeve.

  1. NOTE:
    NOTE:Install a new snap ring.
    Install the needle roller bearing.
    • Install the snap ring.

  1. NOTE:
    NOTE:Observe the markings.
    Assemble the gear synchronizer.
    1. Install the gear synchronizer hub.
    1. Install the selector ring.
    1. Install the blocker bars.
    1. Install the synchronizer springs.

  1. Using the special tool, install the fifth and sixth gear synchronizer and the sixth gear wheel.
    1. Install the sixth gear wheel.
    1. Install the sixth gear synchronizer ring.
    1. Install the fifth and sixth gear synchronizer.

  1. NOTE:
    NOTE:Install a new snap ring.
    Install the fifth gear wheel.
    1. Install the snap ring.
    1. Install the needle roller bearing.
    1. Install the fifth gear wheel.

  1. NOTE:
    NOTE:Install a new snap ring.
    NOTE:
    NOTE:Determine the thickest snap ring for installation.
    Using the special tool, install the transaxle housing roller bearing.
    • Install the snap ring.

Differential > < Output Shaft