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Differential > < Transaxle

Transit 2006.5 (04.2006-)

Manual Transmission/Transaxle - Vehicles With: VXT-75 - Input Shaft Transit 2006.5 (04/2006-)
Disassembly and Assembly of Subassemblies

Special Tool(s)

Remover, Bearing (Main Tool)

205-295 (15-050A)

Collet for 205-295

308-196 (16-061)

Support Plate, Gear Removal (Dia 81.2 mm)

308-229 (16-076)

Support Plate, Gear Removal (Dia 85.1 mm)

308-230 (16-077)
Materials
Name
Specification
Manual transmission fluid
WSD-M2C200-C 

Disassembly
  1. Remove the fifth gear wheel and the roller bearing.
    1. Slide the snap ring up out of the annular grove until it is located below the roller bearing.
    1. Using the special tool, remove the fifth gear wheel with the snap ring and roller bearing.

  1. Remove the fourth gear wheel assembly.
    1. Remove the fourth gear wheel.
    1. Remove the needle roller bearing.
    1. Remove the synchronizer ring.

  1. Remove the third and fourth gear synchronizer assembly.
    • Remove and discard the snap ring.

  1. NOTE:
    NOTE:Take care when removing the synchronizer sleeve from the synchronizer assembly. The detent balls are spring-loaded.
    Disassemble the third and fourth gear synchronizer assembly.
    1. Remove the synchronizer sleeve.
    1. Remove the compression springs, blocker bars and detent balls.

  1. Remove the third gear synchronizer assembly.
    1. Remove the synchronizer ring.
    1. Remove the third gear wheel.
    1. Remove the needle roller bearing.

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

Assembly

  1. NOTE:
    NOTE:When installing new roller bearings, lubricate the roller bearings after the shimming process.
    When installing the original roller bearings, check all parts carefully and lubricate them with clean transmission fluid.

  1. Using a length of suitable tube, install the roller bearing.

  1. Install the third gear synchronizer assembly.
    1. Install the needle roller bearing.
    1. Install the third gear wheel.
    1. Install the third gear synchronizer ring.

  1. Assemble the third and fourth gear synchronizer assembly.
    1. Install the compression springs.
    1. Install the blocker bars and the detent balls.
    1. Install the synchronizer sleeve.

  1. NOTE:
    NOTE:Install the third and fourth gear synchronizer assembly with the larger collar facing outwards (towards the fourth gear wheel).
    NOTE:
    NOTE:Install a new snap ring.
    Install the third and fourth gear synchronizer assembly.
    1. Install the synchronizer assembly.
    1. Install the snap ring.

  1. Install the fourth gear wheel assembly.
    1. Install the synchronizer ring.
    1. Install the needle roller bearing.
    1. Install the fourth gear wheel.

  1. NOTE:
    NOTE:Install the fifth gear wheel with the larger collar facing outwards.
    NOTE:
    NOTE:Install a new snap ring.
    Using a length of suitable tube, install the fifth gear wheel.
    • Install the fifth gear wheel.
    • Install the snap ring.

  1. Using a length of suitable tube, install the roller bearing.

Differential > < Transaxle