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Assembly|Installation > < Differential

Mondeo 2007.5 (02.2007-)

Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75) - Transmission Mondeo 2007.5 (02/2007-)

Assembly

Special Tool(s)
204-017
Installer, Wheel Hub Bearing Cup

204-050
Installer, Front Wheel Hub Bearing Cup/Seal

205-067
Preload Gauge

205-069
Dial Indicator Gauge (Metric)

205-070
Holding Fixture, Dial Indicator Gauge

205-075
Installer, Rear Wheel Hub Seal

205-078
Remover, Drive Pinion Seal

205-078-01
Adapter for 205-078 (Thrust Pad)

205-115
Installer, Drive Pinion Seal

205-175
Socket, Drive Pinion Nut

205-176
Remover, Differential Bearing Cone

205-329
Mounting Bracket, Engine/Differential

303-060
Compressor, Valve Spring

303-060-02
Adapter for 303-060

303-060-07
Adapter for 303-060

303-435
Mounting Stand

303-435-06
Mounting Bracket for 303-435

307-210
Installer, Input Shaft Seal

307-300
Gauge Bar, Shim Selection

308-194B
Holding Fixture, Dial Indicator Gauge (Output Shaft End Play)

308-214
Remover, Hydraulic Line Spring Clip
Materials
Name
Specification
Sealant - Loctite 518
WSK-M2G348-A5
Transmission Fluid
WSD-M2C200-C
General Equipment
Hot air gun
  1.  
    1. Material: Sealant - Loctite 518
    1. Fit the temporary bolt.

  1.  
    1. Remove the temporary bolt.
    1. NOTE:
      NOTE:Make sure that new bolts are installed.
      Torque: 24 Nm

  1.  
    1. General Equipment: Hot air gun
    1. Insert bearing outer rings manually.

  1. Special Tool(s): 204-050, 205-075, 307-210

  1.  
    1. General Equipment: Hot air gun
    1. Install a 1.10 mm measuring shim.
    1. Install 1.00 mm measuring shims.
    1. Insert bearing outer rings manually.

  1. Special Tool(s): 204-017, 204-050, 205-075

  1. NOTE:
    NOTE:Do not oil the taper roller bearing.
    Install the following items:

  1. CAUTION:
    CAUTION:The guide pins must remain installed in the gearbox housing.
    NOTE:
    NOTE:The mounting faces of the component must be clean and free from foreign bodies and lubricant.
    Tighten the bolts in a crisscross sequence.
    Torque: 40 Nm

  1. Special Tool(s): 308-194B

  1. Install the Special Tool(s): 205-069, 205-070, 307-300
  1. Input shaft measurement: Carry out the following two steps three times and calculate the average of the measurements. (Example: (0.22 mm + 0.23 mm + 0.21 mm) / 3 = 0.22 mm)

  1. Special Tool(s): 205-175

  1.  
    1. Pre-load the dial gauge to 1 mm and zero it.
    1. Lift the input shaft with a suitable lever and note the resulting measurement.
  1. Output shaft measurement: Carry out the following three steps three times and calculate the average of the measurements. (Example: (0.32 mm + 0.33 mm + 0.31 mm) / 3 = 0.32 mm)

  1. Special Tool(s): 205-175

  1. Attach the dial gauge, pre-load it to 1 mm and zero it.
    Special Tool(s): 205-069

  1. Lift the output shaft with a suitable lever and note the resulting measurement.

  1. Install the Special Tool(s): 303-060, 303-060-02, 303-060-07
  1. Differential measurement: Carry out the following two steps three times and calculate the average of the measurements. (Example: (0.34 mm + 0.36 mm + 0.38 mm) / 3 = 0.36 mm)

  1.  
    1. Press down the differential during rotation.
      Special Tool(s): 205-175
    1. Pre-load the dial gauge to 1 mm and zero it.
      Special Tool(s): 205-069

  1. Lift the differential with the special tool and note the resulting measurement.
    Special Tool(s): 303-060, 303-060-02
  1.  
    • Calculate the required adjusting shim thickness for the input shaft:
    • Installed measuring shim thickness: 1.00 mm.
    • Calculated average input shaft end float e. g. 0.22 mm.
    • End float constant: -0.07 mm.
    • Shim thickness required: 1.00 mm +0.22 mm -0.07 mm = 1.15 mm
  1.  
    • Calculate the required adjusting shim thickness for the output shaft:
    • Installed measurement shim thickness: 1.00 mm.
    • Calculated average output shaft end float, e.g.: 0.32 mm.
    • Pre-load constant 0.13 mm.
    • Shim thickness required: 1.00 mm +0.32 mm +0.13 mm = 1.45 mm.
  1.  
    • Calculate the required adjusting shim thickness for the differential:
    • Installed measurement shim thickness: 1.10 mm.
    • Calculated average differential end float e. g. 0.36 mm.
    • Pre-load constant 0.33 mm.
    • Shim thickness required: 1.10 mm + 0.36 mm +0.33 mm = 1.79 mm.
  1. Remove the Special Tool(s): 205-069, 205-070, 303-060, 303-060-02, 303-060-07, 307-300, 308-194B

  1. Special Tool(s): 205-176

  1. Special Tool(s): 205-078, 205-078-01

  1.  
    1. General Equipment: Hot air gun
    1. Install the measured adjusting shim.
    1. Install the measured adjusting shim.
    1. Install the measured adjusting shim.
    1. Insert bearing outer rings manually.

  1. Special Tool(s): 204-017, 204-050, 205-075

  1. NOTE:
    NOTE:Make sure that these components are installed to the noted removal position.

  1. Keep the reverse gear idler shaft bearing block raised while installing the shaft.
    Special Tool(s): 308-214

  1. Material: Transmission Fluid

  1.  
    1. Install the input and output shafts together.
    1. Move the input and output shafts to one side.
    1. Remove the Special Tool(s): 308-214

  1. NOTE:
    NOTE:Make sure that these components are installed to the noted removal position.
    Install the following items:

  1. Install the following items:
    1. Material: Sealant - Loctite 518
      Torque: 34 Nm

  1. Material: Sealant - Loctite 518

  1. CAUTION:
    CAUTION:The guide pins must remain installed in the gearbox housing.

  1. Tighten the bolts in a crisscross sequence.
    Torque: 40 Nm

  1.  
    • If the starting torque is too high, all the measurements must be repeated.
    • Starting torque 1 Nm.

  1. Special Tool(s): 205-115

  1. NOTE:
    NOTE:Make sure that a new component is installed.
    Material: Sealant - Loctite 518

  1. Install the following items:
    1. Special Tool(s): 205-115
    1. CAUTION:
      CAUTION:Cover the input shaft splines with adhesive tape to avoid damaging the input shaft oil seal.
      NOTE:
      NOTE:Make sure that a new component is installed.
    1. NOTE:
      NOTE:Make sure that new bolts are installed.
      Torque: 11 Nm
  1. Remove the adhesive tape from the input shaft splines.

  1. Material: Sealant - Loctite 518

  1.  
    1. Torque: 26 Nm
    1. Torque: 26 Nm
    1. Torque: 40 Nm
    1. Remove the Special Tool(s): 205-329, 303-435-06, 303-435

Assembly|Installation > < Differential