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Assembly|Installation > < Synchronizers

Transit 2006.5 (04.2006-)

Manual Transmission/Transaxle - Vehicles With: 6-Speed Manual Transmission (MT82 4x4) - Transmission Transit 2006.5 (04/2006-)

Assembly

Special Tool(s)
204-087
Installer, Front Wheel Hub Bearing Cup/Seal

204-160
Installer, Front Wheel Bearing

204-276
Installer, Wheel Spindle Wear Sleeve

205-052
Installer, Rear Wheel Hub Bearing/Seal

205-067
Preload Gauge

205-072
Universal Flange Holding Wrench

205-175
Socket, Drive Pinion Nut

205-215
Installer, Rear Wheel Hub Seal

205-310
Remover, Bearing/Gear

205-329
Mounting Bracket, Engine/Differential

205-332
Protector, Axle Shaft

303-395
Installer, Crankshaft Seal

303-435
Mounting Stand

303-435-06
Mounting Bracket for 303-435

308-095
Installer, Input Shaft Bearing

308-604
Installer, Output Drive Flange Seal

308-605
Installer, Input Shaft Seal

308-690
Installer, Output Drive Flange Seal

308-691
Wrench, Bearing Housing

308-695
Installer, Inner Driveshaft Seal

308-710
Installer, Bearing Cup
Materials
Name
Specification
Adhesive - Loctite 243
WSK-M2G349-A7
Grease
SA-M1C9107-A
High-Temperature Grease
ESD-M1C220-A
Sealant - Loctite 518
WSK-M2G348-A5
Silicone Sealant
WSE-M4G323-A4
Transmission Fluid
WSD-M2C200-C
General Equipment
Cable ties
Flat-bladed screwdriver
Hot air gun
Hydraulic press
Punch
  1. All synchronizer rings and needle bearings should be lubricated with clean transmission fluid prior to assembly.
    Material: Transmission Fluid

  1. Gear wheel - 4th gear and synchronizer assembly - 3rd/4th gear
    General Equipment: Hydraulic press

  1. Snap ring, synchronizer assembly - 3rd/4th gear

  1. Gear wheel – 6th gear
    Special Tool(s): 308-605
    General Equipment: Hydraulic press

  1. Gear wheel – 5th gear
    Special Tool(s): 308-605
    General Equipment: Hydraulic press

  1. Synchronizer hub – 5th/6th gear
    Special Tool(s): 205-310, 205-332
    General Equipment: Hydraulic press

  1. hot
    General Equipment: Hot air gun

  1. Special Tool(s): 308-095

  1. Torque: 10 Nm

  1. hot
    General Equipment: Hot air gun

  1. Special Tool(s): 205-215

  1. Torque: 10 Nm

  1. NOTE:
    NOTE:Make sure that this component is installed to the noted removal position.

  1. NOTE:
    NOTE:Make sure that these components are installed to the noted removal position.
    Install the following items:
    1. Torque: 27 Nm

  1.  
    1. Secure the shaft pack with cable ties.
      General Equipment: Cable ties
    1. Secure the input shaft to protect it against falling down.

  1. hot
    Special Tool(s): 204-087, 204-160
    General Equipment: Hot air gun

  1.  
    1. Remove the cable tie.

  1. Material: Sealant - Loctite 518

  1.  
    1. NOTE:
      NOTE:Only tighten the bolts finger tight at this stage.
    1. General Equipment: Punch

  1.  
    1. Tighten the transmission housing bolts, working diagonally.
      Torque: 24 Nm
    1. Torque: 37 Nm

  1. Torque: 37 Nm

  1. Torque: 24 Nm

  1. Torque: 24 Nm

  1. Special Tool(s): 308-604
    Material: Grease

  1. hot
    Special Tool(s): 308-604
    General Equipment: Hot air gun

  1. Special Tool(s): 205-332, 308-604

  1. Engage fourth gear.

  1. Material: Sealant - Loctite 518

  1. hot
    1. Special Tool(s): 303-395
      General Equipment: Hot air gun
    1. Transfer the heat to the bearing.

  1. NOTE:
    NOTE:Only tighten the bolts finger tight at this stage.

  1. Align the swinging shift fork using a flat-blade screwdriver if neccessary.
    General Equipment: Flat-bladed screwdriver
    Torque: 37 Nm

  1.  
    1. General Equipment: Punch
    1. Tighten the transmission housing bolts, working diagonally.
      Torque: 24 Nm

  1. Move the gearshift shaft to neutral.

  1. Special Tool(s): 308-690

  1. NOTE:
    NOTE:This step is only necessary when installing a new component.
    If equipped.
    Special Tool(s): 308-690

  1. hot
    General Equipment: Hot air gun

  1.  
    • Loosen the bolt.
    • Tighten the bolt.
      Torque: 180 Nm

  1. Install the following items:
    1. Engage fourth gear.
    1. Special Tool(s): 205-072
    1. Torque: 95 Nm
    1. NOTE:
      NOTE:Make sure that a new component is installed.

  1.  
    • Rotate the transmission shafts and shift the transmission through the gears.
    • Check the torque at idle and with the output flange blocked.
      Special Tool(s): 205-067, 205-175
    • Preload torque max 1.2 Nm.

  1. Install the following items:
    1. Torque: 20 Nm
    1. Material: High-Temperature Grease
      Torque: 8 Nm

  1. Special Tool(s): 308-605

  1. Torque: 11 Nm

  1. NOTE:
    NOTE:Only tighten the bolts finger tight at this stage.
  1. Move the gearshift shaft to neutral.

  1. Torque: 12 Nm

  1. X = 154 mm (gearshift shaft in neutral)
    Torque: 25 Nm

  1. Material: High-Temperature Grease

  1. Special Tool(s): 205-052

  1. Special Tool(s): 205-052

  1. CAUTION:
    CAUTION:Make sure that new bolts are installed.
    Torque: 83 Nm

  1. Special Tool(s): 308-710

  1. Special Tool(s): 308-710

  1. Special Tool(s): 308-695

  1.  
    1. Material: Sealant - Loctite 518

  1. Material: Silicone Sealant

  1. CAUTION:
    CAUTION:Make sure that a new snap ring is installed.

  1.  
    1. Material: Transmission Fluid
    1. Torque: 24 Nm

  1.  
    1. Material: Sealant - Loctite 518

  1. Material: Silicone Sealant

  1.  
    1. Material: Transmission Fluid
    1. Torque: 24 Nm

  1. Install the following items:
    1. Torque: 24 Nm
    1. On both sides.
      Torque: 10 Nm

  1.  
    • On both sides.
    1. Special Tool(s): 308-691
    • Torque: 24 Nm
    • Loosen the bearing and turn the transmission shaft.
    • Torque: 24 Nm
    • Torque: 75 Nm
    1. Torque: 24 Nm

  1. On both sides.
    Special Tool(s): 204-276

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

Assembly|Installation > < Synchronizers