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Disassembly and Assembly of Subassemblies > < Transaxle - 1.8L Diesel

Mondeo 1997 Manual Transmission Removal and Disassembly

Manual Transmission/Transaxle - Transaxle Mondeo 1997 (08/1996-09/2000)
Disassembly

Special Tool(s)

Transmission mounting bracket (in conjunction with 303-435)

303-435-06 (21031B)

Mounting bracket, engine/differential

205-329 (15105A)

Remover, driveshaft oil seal

308-208 (16074)

Installer, differential bearing

205-062 (15025A)

Remover, bearing outer race

205-176 (15074)

Remover, bearing outer race

205-078 (15048)

Adapter

205-078-01 (1504801)
General Equipment
Assembly stand

Disassembly

All vehicles
  1. Attach the special tools.
Vehicles built up to 10/1999 inclusive
  1. NOTE:
    NOTE:Make sure the selector mechanism is in neutral.
    Remove the selector mechanism.
    • Remove the bolts.
    • Pry off with a screwdriver.
Vehicles built from 11/1999
  1. Detach the shift mechanism cover.

  1. NOTE:
    NOTE:Make sure the selector mechanism is in neutral.
    Remove the selector mechanism.
All vehicles
  1. Using the special tool, remove the front driveshaft oil seals.
Vehicles with diesel engine
  1. NOTE:
    NOTE:Only required for sealing repairs.
    Remove the speedometer drive pinion.
Vehicles with 1.6, 1.8 or 2.0 engine
  1. NOTE:
    NOTE:Only required for sealing repairs.
    Remove the vehicle speed sensor (VSS).
All vehicles
  1. NOTE:
    NOTE:Do not remove the locating dowels.
    Undo the transmission housing bolts.

  1. CAUTION:
    CAUTION:Do not damage the transmission housing.
    Separate the transmission housing sections.
    1. Use a block underneath the lever to avoid damaging the housing.
    1. Separate the transmission housing sections using two levers on opposite sides.

  1. NOTE:
    NOTE:Only for sealing work or renewal.
    Undo the clutch slave cylinder.

  1. NOTE:
    NOTE:Discard the clutch slave cylinder.
    Remove the clutch slave cylinder (with release bearing).

  1. NOTE:
    NOTE:Slightly tilt the differential.
    Remove the differential assembly.
    • Remove the magnetic disk.

  1. Unscrew the bolts from the reverse gear idler shaft mounting.

  1. Remove the selector rods and the 1st/2nd gear selector fork.

  1. Remove the selector forks.
    1. Swing the 5th/reverse gear selector fork to the side.
    1. Turn the 3rd/4th gear selector fork and remove it.
    • Remove the 5th/reverse gear selector fork.

  1. Remove the reverse gear idler shaft mounting.
    1. Swing the input shaft and output shaft to the side (the reverse gear idler shaft mounting should lift up).
    1. Remove the mounting.
    • The reverse gear idler remains in the transmission.

  1. Remove the input shaft and the output shaft.
    • Lever the input shaft and the output shaft together out of the transmission housing.
    • Take out the reverse gear idler together with the needle roller bearing and the thrust washers.

  1. Remove the differential bearing outer race.
    • Locate the special tool on the recesses in the housing.

  1. Remove the outer races of the input shaft and output shaft bearings.
    • Locate the special tool on the recesses in the housing.

  1. Remove the bearing outer races and shims of the differential and input shaft.
    • Locate the special tool on the recesses in the housing.

  1. Remove the bearing outer race of the output shaft with the shim.
    • Locate the special tool on the recesses in the housing.

  1. NOTE:
    NOTE:Only when damaged or leaking.
    Remove the reverse gear idler shaft.

  1. NOTE:
    NOTE:Only when damaged or leaking.
    Remove the reverse gear idler shaft.
    • Drive it out using a block of hard wood.

Disassembly and Assembly of Subassemblies > < Transaxle - 1.8L Diesel