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Home › Ford › 2012 › Fiesta SES, Standard Trans › Repair and Diagnosis › Transmission › Manual Trans › Manual Transaxle (IB5) › Disassembly › Transaxle › All Transmissions

All Transmissions

  1. Using the special tool, install the transaxle.
    Fig 1: Installing Transaxle Using Special Tool
    G06938083Courtesy of FORD MOTOR CO.
  2. Remove the clutch slave cylinder.
    1. Remove the 3 clutch slave cylinder bolts.
    2. Remove the clutch slave cylinder.
    Fig 2: Locating Clutch Slave Cylinder And Bolts
    G06938084Courtesy of FORD MOTOR CO.
  3. Remove the Vehicle Speed Sensor (VSS).
    1. Remove the retaining pin.
    2. Remove the VSS  .
    Fig 3: Identifying Vehicle Speed Sensor And Retaining Pin
    G06938085Courtesy of FORD MOTOR CO.
  4. Remove the reversing lamp switch.
    Fig 4: Locating Reversing Lamp Switch
    G07980063Courtesy of FORD MOTOR CO.
  5. Remove the gearshift cables shroud retainers and the gearshift cables shroud.
    Fig 5: Locating Gearshift Cables Shroud Retainers
    G06938086Courtesy of FORD MOTOR CO.
  6. Remove the selector lever.
    1. Remove the protective cap.
    2. Remove and discard the snap-ring and remove the selector lever.
    Fig 6: Identifying Protective Cap And Snap-Ring Of Selector Lever
    G06938087Courtesy of FORD MOTOR CO.
  7. Remove the 2 gearshift cables bracket nuts and remove the gearshift cables bracket.
    Fig 7: Locating Gearshift Cables Bracket Nuts
    G06938088Courtesy of FORD MOTOR CO.
  8. Remove the shift lever snap ring and remove the shift lever.
    Fig 8: Locating Shift Lever Snap Ring
    G06938089Courtesy of FORD MOTOR CO.
  9. Remove the selector shaft interlock mechanism.
    Fig 9: Locating Selector Shaft Interlock Mechanism
    G06938090Courtesy of FORD MOTOR CO.
  10. Remove the 5th gear cover bolts and remove the 5th gear cover.
    Fig 10: Locating 5th Gear Cover Bolts
    G06938091Courtesy of FORD MOTOR CO.

    Transmissions with Old Style Synchronizer 

  11. Remove the 5th gear synchronizer unit, selector fork and 5th gear.
    1. Remove and discard the circlip.
    2. Remove and discard the roll pin.
    Fig 11: Removing 5th Gear Synchronizer Unit, Selector Fork And 5th Gear
    G06938092Courtesy of FORD MOTOR CO.
    12. NOTE: Mark the installation position of the gear synchronizer before disassembling.
    Fig 12: Exploded View Of 5th Gear Synchronizer Unit
    G07980071Courtesy of FORD MOTOR CO.
  12. Disassemble the 5th gear synchronizer unit.
    1. Remove the retention plate
    2. Remove the synchronizer assembly
    3. Remove the synchronizer ring
    4. Remove the 5th gear
  13. Remove and discard the 5th gear snap ring.
    Fig 13: Locating 5th Gear Snap Ring
    G06938094Courtesy of FORD MOTOR CO.

    Transmissions with New Style Synchronizer and All Replacement Synchronizers 

    14. NOTE: Note the position of the components before removal.
    Fig 14: Removing 5th Gear Synchronizer Unit And Selector Fork
    G07980073Courtesy of FORD MOTOR CO.
  14. Remove the 5th gear synchronizer unit and selector fork.
    1. Remove and discard the circlip.
    2. Remove and discard the roll pin.
    15. NOTE: Note the position of the components before removal.
    Fig 15: Inspecting Synchronizer Assembly
    G07980074Courtesy of FORD MOTOR CO.
  15. Disassemble the synchronizer assembly.
  16. Remove and discard the 5th gear snap ring and remove the mainshaft 5th gear.
    Fig 16: Removing 5th Gear Snap Ring
    G07980075Courtesy of FORD MOTOR CO.

    All Transmissions 

  17. Using the special tool, remove the 5th gear.
    Fig 17: Removing 5th Gear Using Special Tool
    G06938095Courtesy of FORD MOTOR CO.
    18. NOTE: Do not strike directly on the gear housing mating surfaces or damage can occur.
    Fig 18: Identifying 5th Gear Housing Mating Surfaces And Bolts
    G06938096Courtesy of FORD MOTOR CO.
  18. Remove the 5th gear housing.
    1. Remove and discard the 9 bolts and carefully separate the 5th gear housing sections by tapping lightly.
    2. Using Motorcraft® Metal Surface Prep, clean the 5th gear housing mating surfaces.
  19. Remove the input shaft and output shaft retaining rings.
    1. Remove and discard the input shaft retaining ring.
    2. Remove and discard the output shaft retaining ring.
    Fig 19: Identifying Input Shaft And Output Shaft Retaining Rings
    G06938097Courtesy of FORD MOTOR CO.
  20. Remove the LH and RH halfshaft seals.
    21. NOTE: Do not use metal scrapers to clean the transaxle gear housing surfaces or damage can occur.
    NOTE: Slightly turn the transaxle housing to raise it.
    Fig 20: Locating Transaxle Housing And Clutch Housing Mating Surfaces Cleaning Area
    G06938098Courtesy of FORD MOTOR CO.
  21. Separate the transaxle housing from the clutch housing.
    • Using Motorcraft® Metal Surface Prep, clean the transaxle housing and clutch housing mating surfaces.
  22. Remove the upper snap-ring from the selector rod guide sleeve.
    1. Remove and discard the upper snap-ring.
    2. Push the selector rod guide sleeve downwards.
    Fig 21: Pushing Selector Rod Guide Sleeve Downwards
    G06938099Courtesy of FORD MOTOR CO.
  23. Remove the selector rod guide sleeve.
    1. Remove and discard the lower snap-ring from the guide sleeve.
    2. Pull off the selector rod guide sleeve.
    Fig 22: Pulling Off Selector Rod Guide Sleeve
    G06938100Courtesy of FORD MOTOR CO.
    24. NOTE: Install a rubber belt to the auxiliary selector shaft to aid disassembly.
    Fig 23: Removing Input And Output Shaft With Shift Forks
    G06938101Courtesy of FORD MOTOR CO.
  24. Remove the input and output shaft with the shift forks.
  25. Remove the differential and the magnet.
    Fig 24: Locating Differential And Magnet
    G06938102Courtesy of FORD MOTOR CO.
  26. Remove the reverse idle gear.
    Fig 25: Locating Reverse Idle Gear
    G06938103Courtesy of FORD MOTOR CO.
  27. Remove the selector rod and locking plate.
    1. Remove the selector interlock plate.
    2. Remove the 5th/reverse gear selector rod.
    Fig 26: Identifying Selector Interlock Plate And 5th/Reverse Gear Selector Rod
    G06938104Courtesy of FORD MOTOR CO.
  28. Remove and discard the input shaft oil seal.
    Fig 27: Locating Input Shaft Oil Seal
    G06938105Courtesy of FORD MOTOR CO.
  29. Remove output shaft roller bearing.
    • Press out the track rollers from the bearing cage.
    • Remove the bearing cage.
    Fig 28: Locating Output Shaft Roller Bearing
    G06938106Courtesy of FORD MOTOR CO.
    30. NOTE: Only use the special tool in the position indicated, otherwise the blanking plug will be forced out of the housing.
    Fig 29: Removing Output Shaft Bearing Cone Using Special Tool
    G06938107Courtesy of FORD MOTOR CO.
  30. Using the special tool, remove the output shaft bearing cone.
    • Remove the oil thrower.
  31. Remove the bearing cone.
    Fig 30: Removing Bearing Cone
    G06938108Courtesy of FORD MOTOR CO.
  32. Using the special tool, remove the differential bearing cone.
Fig 31: Removing Differential Bearing Cone Using Special Tool
G06938109Courtesy of FORD MOTOR CO.
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