Primary shaft — disassembly and assembly (Focus 1)

Special tool

	Bearing puller (main tool) 205-295 (15-050A)
	Clamp for 205-295 308-195 (16-060)
	Clamp for 205-295 308-196 (16-061)
	Thrust element for removing gears 308-198 (16-063)
	Gear Removal Plate (85.1mm Diameter) 308-230 (16-077)

General equipment: Press.

Name	Specification
Transmission fluid	WSD-M2C200-C

Disassembly

All cars

1.

CAUTION: The inner ring and conical ring of the synchronizer must be handled with extreme care.

General notes

The 1.8L Endura-DI diesel engine has been fitted to Focus models since the first quarter of 1999.
General view of the primary shaft: For additional information, refer to the Description and Purpose chapter in this section.

CAUTION: Use a vise with jaw guards.

Clamp the axle shaft in a vice.

3. Remove the tapered roller bearing from the clutch side.

4. Remove the tapered roller bearing from the transmission case side.

All except diesel vehicles

5.

NOTE: Remove the gears using a suitable press.

NOTE: Discard the snap ring as it is no longer needed.

Disconnect the 5th gear.

1. Disconnect the snap ring.
2. Disconnect the gear using a special tool.

2. Disconnect the gear using a special tool.

Diesel Engine Cars

6.

NOTE: Remove the gears using a suitable press.

NOTE: Discard the snap ring as it is no longer needed.

Disconnect the 5th gear.

1. Remove the retaining ring.
2. Remove the gear using a special tool.

2. Remove the gear using a special tool.

All cars

7. Disconnect the 4th gear.

1. Disconnect the gear.
2. Remove the needle bearing.
3. Disconnect the synchronizer ring.

NOTE: Discard the snap ring as it is no longer needed.

Disconnect the 3rd/4th gear synchronizer assembly.

1. Remove the retaining ring.
2. Disconnect the synchronizer assembly.

2. Disconnect the synchronizer assembly.

NOTE: Mark the installation position of the synchronizer sleeve relative to the synchronizer hub in readiness for installation. The elements work in pairs.

NOTE: Carefully remove the synchronizer sleeve from the synchronizer hub. The locking balls are under spring force.

Synchronizer 3rd/4th gear assembly. Disassemble the gear.

1. Remove the synchronizer sleeve.
2. Synchronizer hub
3. Compression spring
4. Rusk
5. Stopper ball

Cars manufactured up to 08.2001.

10. Remove the double synchronizer together with the 3rd gear.

1. Outer synchronizer ring
2. Conical synchronizer ring
3. Inner synchronizer ring
4. 3rd gear pinion
5. Needle roller bearing

Cars manufactured since 08.2001.

11. Disconnect the 3rd gear.

1. Disconnect the synchronizer ring.
2. Disconnect the gear.
3. Remove the needle bearing.

Assembly

All cars

1.

NOTE: Install new tapered roller bearings (unmachined).

Carefully clean and inspect all components. Apply transmission fluid to them before assembly.

2. Press the tapered roller bearing on the clutch side.

Press on the tapered roller bearing using a suitable piece of pipe and a press.

Press on the tapered roller bearing using a suitable piece of pipe and a press.

Cars manufactured up to 08.2001.

3. Install the 3rd gear pinion together with the double synchronizer and needle bearing.

1. Needle roller bearing
2. 3rd gear pinion
3. Inner synchronizer ring
4. Conical synchronizer ring
5. Outer synchronizer ring

Cars manufactured since 08.2001.

4. Install the 3rd gear.

1. Install the needle roller bearing.
2. Install the 3rd gear.
3. Install the synchronizer ring.

All cars

5.

NOTE: Pay attention to the markings.

3rd/4th gear synchronizer. Assemble the gear.

1. Insert the compression springs.
2. Insert the synchronizer crackers and locking balls by pressing them in against the spring force.
3. Install the synchronizer sleeve.