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Section 1 (Manual Transaxle): Assembly: Transmission

WARNING: This page is about a different variant/trim than selected.
SPECIAL TOOLS/GENERAL EQUIPMENT

G08062760
 100-002  (TOOL-4201-C)
Holding Fixture with Dial Indicator Gauge
G08064740
 205-075
Installer, Rear Wheel Hub Seal
G06292978
 205-115 
Installer, Drive Pinion Seal
TKIT-2000-F/FM/FLM
G08062419
 303-350  (T89P-6565-A)
Compressor, Valve Spring
TKIT-1989-F
TKIT-1989-FM
TKIT-1989-FLM
TKIT-1990-LMH
G08636546
 307-003  (T57L-500-B)
Holding Fixture, Transmission
G08064259
 307-680 
Table, Assembly (DPS6)
G08638226
 308-847
Installer, Input shaft Seal
G08638398
 308-849
Installer Shift Shaft Bushing
G08638198
 308-880
Installer, Driveshaft Seal
Hot Air Gun
Punch
Adhesive Tape
MATERIALS SPECIFICATIONS

Name Specification
Gasket Maker
TA-16		 WSK-M2G348-A5
Motorcraft® Dual Clutch Transmission Fluid
XT-11-QDC		 WSS-M2C200-D2
Silicone Brake Caliper Grease and Dielectric Compound
XG-3-A		 ESE-M1C171-A
    1. 1.
      NOTE: In order to avoid incorrect readings, do not oil the taper roller bearings.

      General Equipment  : Hot Air Gun

    2. 3. Special Tool(s)  : 205-075 Installer, Rear Wheel Hub Seal
      G08638400
  2. Special Tool(s)  : 205-075 Installer, Rear Wheel Hub Seal
    G08638401
    1. 1. General Equipment  : Hot Air Gun
    2. 3. Special Tool(s)  : 205-075 Installer, Rear Wheel Hub Seal
      G08638402
  4. Special Tool(s)  : 205-075 Installer, Rear Wheel Hub Seal
    G08638403
  5. NOTE: The surfaces must be thoroughly cleaned.

    Tighten the bolts in a crisscross sequence.

    Torque  : 18 Nm

    G08638404
  6. NOTE: Clean the end face of the differential assembly and mark it at one place.

    Install Special Service Tool  : 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge 

    G08638405
  7. Repeat this and the following three steps three times and determine the average values. Special Tool(s)  : 303-350 (T89P-6565-A) Compressor, Valve Spring 
    G08638406
    • Turn the differential until the measuring pin is on the marked spot.
    • Pre-load the dial gauge to 1 mm and zero it.

      Install Special Service Tool  : 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge 

      G08638407
  9. G08638408
    1. Special Tool(s)  : 303-350 (T89P-6565-A) Compressor, Valve Spring 
    2. Turn the differential until the measuring pin is on the marked spot.
    3. Measure the differential end float: Make a note of the measurement; Example: 0.265 mm + 0.255 mm + 0.260 mm, divided by 3 = 0.260 mm.
      G08638409
    • Determine the thickness of the differential adjusting shim:
    • Determined differential end float is X mm.
    • Differential bearing pre-load 0.14 mm.
    • Required adjusting shim thickness: X mm + 0.14 mm = X mm.
    • Determined adjusting shim thickness.
    • If the determined adjusting shim thickness is unequal, then use the next closest thickness of adjusting shim.
  12. Remove Special Service Tool  : 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge 
  13. G08638404
  14. General Equipment  : Punch
    G08638411
  15. Special Tool(s)  : 308-849 Installer Shift Shaft Bushing
    G08638412
    1. General Equipment  : Hot Air Gun
    2. Determined adjusting shim.
      G08638413
  17. Special Tool(s)  : 308-880 Installer, Driveshaft Seal
    G08638414
  18. Special Tool(s)  : 205-075 Installer, Rear Wheel Hub Seal, 205-115 Installer, Drive Pinion Seal 
    G08638415
  19. Special Tool(s)  : 308-849 Installer Shift Shaft Bushing

    Material  : Motorcraft® Dual Clutch Transmission Fluid/XT-11-QDC (WSS-M2C200-D2)

    G08638416
  20. Special Tool(s)  : 308-849 Installer Shift Shaft Bushing
    G08638417
  21. Material  : Silicone Brake Caliper Grease and Dielectric Compound/XG-3-A (ESE-M1C171-A)
    G08638418
  22. Material  : Silicone Brake Caliper Grease and Dielectric Compound/XG-3-A (ESE-M1C171-A)
    G08638419
  23. Material  : Motorcraft® Dual Clutch Transmission Fluid/XT-11-QDC (WSS-M2C200-D2)
    G08638420
    1. 2.
      NOTE: Take extra care not to damage the bearing.

      Material  : Motorcraft® Dual Clutch Transmission Fluid/XT-11-QDC (WSS-M2C200-D2)

      G08638421
  25. G08638422
  26. NOTE: Take extra care not to damage the bearings.
    1. 1. Material  : Motorcraft® Dual Clutch Transmission Fluid/XT-11-QDC (WSS-M2C200-D2)
    2. 3.
      NOTE: Take extra care when handling the component.
    3. 5. Material  : Motorcraft® Dual Clutch Transmission Fluid/XT-11-QDC (WSS-M2C200-D2)
      G08638423
    1. 2. Material  : Motorcraft® Dual Clutch Transmission Fluid/XT-11-QDC (WSS-M2C200-D2)
      G08638424
    1. Install Special Service Tool  : 307-680 Table, Assembly (DPS6) 
    2. Material  : Gasket Maker/TA-16 (WSK-M2G348-A5)
      G08638425
    1. NOTE: Make sure that new bolts are installed.

      Torque  :

      Stage 1: 18 Nm

      Stage 2: 90°

    2. Remove Special Service Tool  : 307-680 Table, Assembly (DPS6) 
      G08638426
    1. NOTE: Make sure that new bolts are installed.

      Torque  :

      Stage 1: 18 Nm

      Stage 2: 90°

    2. NOTE: Make sure that new bolts are installed.

      Material  : Gasket Maker/TA-16 (WSK-M2G348-A5)

    3. Torque  : 20 Nm
    1. 5. Special Tool(s)  : 308-880 Installer, Driveshaft Seal
      G08638427
  31. G08638428
  32. NOTE: Re-use the O-ring seal unless it is damaged.

    Material  : Motorcraft® Dual Clutch Transmission Fluid/XT-11-QDC (WSS-M2C200-D2)

    G08638239
    1. NOTE: Make sure that the selector lever is in the neutral (N) position.
    2. NOTE: Make sure that no components catch.
    3. Torque  : 24 Nm
      G08638430
  34. Torque  : 24 Nm
    G08638298
    1. 1.
      NOTE: Use adhesive tape to cover the input shaft splines to prevent damage to the input shaft seal.

      General Equipment  : Adhesive Tape

    2. 3. Special Tool(s)  : 308-847 Installer, Input shaft Seal
      G08638230
    1. 1. Torque  :

      Stage 1: 18 Nm

      Stage 2: 90°

    2. 2. Torque  : 10 Nm
    3. 4. Special Tool(s)  : 308-880 Installer, Driveshaft Seal
    4. 5. Remove Special Service Tool  : 307-003 (T57L-500-B) Holding Fixture, Transmission 
      G08638433
  37. If equipped.

    Torque  : 48 Nm

    G08638296
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