Secondary shaft — disassembly and assembly (Focus 1)

Special tool

	Bearing Puller (Main Tool) 205-295 (15-050A)
	Crankcase Extended Part Bushing/Oil Seal Installer 308-045 (16-015)
	Collet for 205-295 307-217 (17-048)

General equipment:

• Double support puller
• Press
• Retaining ring

Name	Specification
Transmission fluid for manual transmission	WSD-M2C200-C

Disassembly

1. Remove the roller bearing and fourth gear.

• 1. Remove the small snap ring and discard it as no longer needed.
• 2. Install the appropriate snap ring.
• 3. Using a suitable double bearing puller, remove the roller bearing.
• 4. Remove the fourth gear pinion and synchronizer ring.

2. Remove the third and fourth gear synchronizer assembly.

• 1. Remove the snap ring and discard it as no longer needed.
• 2. Remove the synchronizer, third and fourth gear synchronizer assembly and third gear gear.

3. Remove the third gear synchronizer ring from the third gear gear.

• 1. Outer synchronizer ring
• 2. Conical synchronizer ring
• 3. Third gear.

4.

NOTE: Dual synchronizer shown, this is a service replacement item.

Disassemble the third gear synchronizer assembly.

• 1. Outer synchronizer ring
• 2. Conical synchronizer ring
• 3. Inner synchronizer ring
• 4. Third gear.

5. Remove the second gear pinion and synchronizer assembly.

• 1. Retaining ring
• 2. Retaining rings
• 3. Second gear pinion
• 4. Inner synchronizer ring
• 5. Conical synchronizer ring
• 6. Outer synchronizer ring

6.

NOTE: Remove the synchronizer assembly together with the first gear.

Remove the first gear pinion and reverse gear pinion, synchronizer and synchronizer assembly.

• 1. Remove the snap ring and discard it as no longer needed.
• 2. Remove the first and second gear synchronizer and the reverse gear pinion.
• 3. Outer synchronizer ring
• 4. Conical synchronizer ring
• 5. Inner synchronizer ring
• 6. First gear pinion.

7.

CAUTION: To facilitate assembly, mark the position of the synchronizer sleeve relative to the synchronizer hub.

Disassemble the synchronizer hub.

• 1. Synchronizer clutch
• 2. Synchronizer spring
• 3. Synchronizer cracker
• 4. Synchronizer hub

8.

NOTE: Install the stop into the oil funnel opening.

Using special tools, remove the secondary shaft inner bearing.

• 1. Remove the snap ring and discard it as no longer needed.
• 2. Install the special tools below the bearing inner ring.

Assembly

CAUTION: Before assembly, soak the dual synchronizer assembly in clean manual transmission fluid.

1. Before assembly, thoroughly clean and inspect all working surfaces and apply clean manual transmission fluid to them.

2.

NOTE: Install a new secondary shaft bearing inner race snap ring.

Install the secondary shaft bearing inner race.

• Heat the bearing inner ring uniformly to approximately 80°C and install it on the secondary shaft.
• Install the retaining ring.

3.

NOTE: Assemble the synchronizer hub according to the marks.

Assemble the synchronizer hub.

• 1. Synchronizer hub
• 2. Install the synchronizer sleeve onto the synchronizer hub.
• 3. Install the synchronizer blocks.
• 4. Install the synchronizer spring.

4.

NOTE: Use a new 1st and reverse gear snap ring.

Install the first and reverse gear pinion, synchronizer and synchronizer assembly.

• 1. First gear pinion.
• 2. Inner synchronizer ring
• 3. Conical synchronizer ring
• 4. Outer synchronizer ring
• 5. Install the first and second gear synchronizer and the reverse gear pinion.
• 6. Install the retaining ring.

5.

NOTE: Assemble the synchronizer assembly before installing it on the secondary shaft.

Install the second gear pinion with synchronizer assembly.

• 1. Outer synchronizer ring
• 2. Conical synchronizer ring
• 3. Inner synchronizer ring
• 4. Second gear pinion
• 5. Retaining rings
• 6. Retaining ring

6.

NOTE: Dual synchronizer shown, this is a service replacement item.

Assemble the third gear synchronizer assembly.

• 1. Third gear.
• 2. Inner synchronizer ring
• 3. Conical synchronizer ring
• 4. Outer synchronizer ring

7. Install the third gear synchronizer ring onto the third gear pinion.

• 1. Third gear.
• 2. Conical synchronizer ring
• 3. Outer synchronizer ring

8.

NOTE: Install a new 3rd/4th gear synchronizer snap ring assembly.

NOTE: Install the synchronizer sleeve so that the annular groove faces down and the small projection of the hub faces up.

Install the third and fourth gear synchronizer assembly.

• 1. Install the synchronizer, third and fourth gear synchronizer assembly and third gear gear.
• 2. Install the retaining ring.

9.

NOTE: Install a new roller bearing snap ring.

NOTE: Install the roller bearing with the annular groove facing outward.

Using the special tool and an appropriate press, install the fourth gear pinion and roller bearing.

• 1. Install the synchronizer ring and fourth gear.
• 2. Using a suitable press, install the roller bearing.
• Install the retaining ring.

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