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Assembly|Installation > < Differential - VIN Plate Axle Code: H-J-K

Transit 2006.5 (04.2006-)

Manual Transmission/Transaxle - Vehicles With: 6-Speed Manual Transmission (VMT6) - Transmission Transit 2006.5 (04/2006-)

Assembly

Special Tool(s)
205-044-01
Adapter for 205-044

205-069
Dial Indicator Gauge (Metric)

205-070
Holding Fixture, Dial Indicator Gauge

205-073
Installer, Differential Bearing Cone

205-081
Installer, Differential Bearing

205-115
Installer, Drive Pinion Seal

205-175
Socket, Drive Pinion Nut

205-217
Installer, Rear Wheel Hub Bearing Cone/Seal

205-315
Installer, Drive Pinion Seal

205-329
Mounting Bracket, Engine/Differential

206-003
Holding Fixture, Dial Indicator Gauge (Disc Brake)

303-435
Mounting Stand

303-435-06
Mounting Bracket for 303-435

307-300-02
Depth Gauge, Shim Selection

307-300-03
Adapter for 307-300-02

307-430
Gauge, Transmission End Play

308-044
Installer, Transmission Extension Housing Bushing/Seal

308-112
Installer, Output Drive Flange Seal

308-603
Gauge, Differential/Transfer Gear Bearing Shim

308-605
Installer, Input Shaft Seal
Materials
Name
Specification
Sealant - Loctite 518
WSK-M2G348-A5
Transmission Fluid
WSS-M2C200-D
General Equipment
Cable ties
Hot air gun
Punch
NOTE:
NOTE:Do not oil taper roller bearings.
  1. NOTE:
    NOTE:Make sure that a new component is installed.
    Special Tool(s): 308-044

  1.  
    1. General Equipment: Hot air gun
    1. NOTE:
      NOTE:Make sure that new components are installed.

  1. Special Tool(s): 205-217, 205-315

  1.  
    1. General Equipment: Hot air gun
    1. NOTE:
      NOTE:Make sure that a new component is installed.
    1. Measuring shim 1.10 mm
    1. NOTE:
      NOTE:Make sure that a new component is installed.

  1. Special Tool(s): 205-081, 205-315

  1.  
    1. CAUTION:
      CAUTION:Take extra care not to damage the bearings.
      CAUTION:
      CAUTION:Extreme cleanliness must be exercised when handling these components.
    1. NOTE:
      NOTE:Make sure that new components are installed.
    1. Special Tool(s): 308-603

  1.  
    • Repeat this and the following six steps three times and determine the average values.
    • Lift the measuring rings to approx. 10 mm.
      Special Tool(s): 308-603

  1. Hold the bearing outer race and press down the special tool at the same time.

  1. Hold the bearing outer race and press down the special tool at the same time.

  1. Special Tool(s): 205-070, 206-003, 307-430

  1. Torque: 40 Nm

  1.  
    • Record the measurement results.
  1.  
    • Measure the required thickness of the 1st - 4th gear output shaft adjustment shim:
    • Add the measured values, divide by three and then add the value for the bearing pre-load.
    • 1st - 4th gear output shaft bearing pre-load: 0.17 mm.
    • Example: 1.56 mm + 1.57 mm + 1.55 mm, divided by 3 = 1.56 mm. 1.56 mm + 0.17 mm = 1.73 mm.
    • Determined adjusting shim thickness: 1.73 mm.
    • If the thickness of the measured shim is odd, select the shim with the next higher thickness value.
  1.  
    • Measure the required thickness of the 5th/6th gear/reverse gear output shaft adjustment shim:
    • Add the measured values, divide by three and then add the value for the bearing pre-load.
    • Bearing pre-load - output shaft - 5th/6th/reverse gear: 0.15 mm.
    • Example: 1.51 mm + 1.52 mm + 1.50 mm, divided by 3 = 1.51 mm. 1.51 mm + 0.15 mm = 1.66 mm.
    • Determined adjusting shim thickness: 1.66 mm.
    • If the thickness of the measured shim is odd, select the shim with the next higher thickness value.

  1. Remove the following items:
    1. Special Tool(s): 308-603

  1. Install the following items:
    1. General Equipment: Hot air gun
    1. NOTE:
      NOTE:Make sure that new components are installed.
    1. Measured adjusting shim
    1. Measured adjusting shim

  1. Special Tool(s): 205-073, 308-605

  1. Tighten the transmission housing bolts in two stages, working diagonally.
    Torque: 40 Nm

  1. Clean the end face of the differential assembly and mark it at one place.
    Special Tool(s): 205-070, 205-044-01

  1. Repeat this and the following four steps three times and determine the average values.
    Special Tool(s): 205-175

  1.  
    • Turn the differential until the measuring pin is on the marked spot.
    • Pre-load the dial gauge to 1 mm and zero it.
      Special Tool(s): 205-069

  1. Special Tool(s): 205-175

  1.  
    1. Turn the differential until the measuring pin is on the marked spot.
    1. Measure the differential end float: Make a note of the measurement. Example: 0.34 mm + 0.36 mm + 0.38 mm, divided by 3 = 0.36 mm.
  1.  
    • Determine the thickness of the differential adjusting shim:
    • Installed measuring shim thickness: 1.10 mm.
    • Determined differential end float 0.36 mm
    • Differential bearing pre-load 0.20 mm.
    • Required adjusting shim thickness: 1.10 mm + 0.36 mm + 0.20 mm = 1.66 mm.
    • Determined adjusting shim thickness: 1.66 mm.
    • If the thickness of the measured shim is odd, select the shim with the next higher thickness value.
  1. Remove the Special Tool(s): 205-044-01, 205-069, 205-070, 206-003

  1. Remove the following items:
    1. General Equipment: Punch
    1. Measuring shim

  1.  
    1. General Equipment: Hot air gun
    1. Measured adjusting shim

  1. Special Tool(s): 205-315

  1. Install the Special Tool(s): 205-070, 206-003
    General Equipment: Cable ties
    Material: Transmission Fluid

  1.  
    • Remove the cable ties.

  1.  
    1. NOTE:
      NOTE:Only tighten the bolt finger tight at this stage.
    1. Remove the Special Tool(s): 205-070, 206-003

  1. Material: Transmission Fluid

  1. Material: Sealant - Loctite 518

  1. CAUTION:
    CAUTION:Use adhesive tape to cover the input shaft splines to prevent damage to the input shaft seal.
    1. NOTE:
      NOTE:Make sure that a new component is installed.
    1. Special Tool(s): 308-112
  1. Remove the adhesive tape.

  1.  
    1. NOTE:
      NOTE:Only tighten the bolts finger tight at this stage.
    1. General Equipment: Punch
    1. Torque: 11 Nm

  1.  
    1. NOTE:
      NOTE:Only tighten the bolts finger tight at this stage.
    1. General Equipment: Punch
    1. NOTE:
      NOTE:Make sure that a new component is installed.
    1. Special Tool(s): 205-115
    1. If equipped.

  1. Material: Sealant - Loctite 518

  1.  
    1. Tighten the transmission housing bolts in two stages, working diagonally.
      Torque: 40 Nm
    1. Torque: 40 Nm
    1. Torque: 26 Nm

  1. Torque: 40 Nm

  1.  
    1. Torque: 30 Nm
    1. CAUTION:
      CAUTION:Make sure that new bolts are installed.
      Torque: 30 Nm
    1. NOTE:
      NOTE:Make sure that a new component is installed.
    1. Special Tool(s): 205-115
    1. Remove the Special Tool(s): 205-329, 303-435, 303-435-06

Assembly|Installation > < Differential - VIN Plate Axle Code: H-J-K