Gearbox in block with driving axle — assembly (Power unit / Mechanical gearbox MTX-75 / Ford Focus 1 1998-2004)

Special tool

	Bearing Outer Ring and Oil Seal Installation Tool 204-017 (14-010)
	Bearing Outer Ring and Oil Seal Installation Tool 204-050 (14-024)
	Torque Measuring Device 205-067 (15-041)
	Bearing Outer Ring Installation Tool 205-075 (15-036)
	Differential Oil Seal Installation Tool 205-115 (15-058)
	Socket head 205-175 (15-073)
	Valve Spring Compressor 306-060 (21-024)
	Adapter for 306-060 306-060-02 (21-024-02)
	Adapter for 306-060 306-060-07 (21-024-07)
	Primary Shaft Oil Seal Installation Tool 307-210 (17-041)
	Device for measuring axial clearance of the primary shaft 308-194 (16-059A)

General equipment:

Press
Dial indicator
Tripod with magnetic base for dial indicator
Steel plate (eg 303-435-11 (21-146C))

Name	Specification
Transmission fluid	WSD-M2C200-C
Sealant	WSK-M2G348-A5
Clutch slave cylinder sealant	ESK-M4G269-A
High temperature grease	ESDM-1C220-A

Assembly

All cars

1.

NOTE: 1.8L Endura-DI offered beginning with the 1999 model year.

Before assembly, carefully clean and check all components.

Lubricate all working surfaces. Transmission fluid is used for this purpose.

NOTE: Only if removed

Install the reverse gear intermediate gear shaft.

1. Apply sealant to the mating surface of the reverse gear intermediate gear shaft.
2. Align the reverse gear intermediate gear shaft with the adjusting bolt and install it in place.
3. Remove the mounting bolt and screw in the original bolts.

CAUTION: Maximum press force 15 kN.

Install the inner bearing races from the gearbox housing side.

Using a heat gun, heat the crankcase area to approximately 80°C.
Cool the inner bearing races using a temperature reducing spray and install them.
Install the inner bearing rings:
primary shaft using special tool 307-210 (17-041)
secondary shaft using special tool 205-075 (15-036)
differential using special tool 204-050 (14-024)

4. Measuring gasket to be installed on:

primary shaft: 1.00 mm
secondary shaft: 1.00 mm
differential: 1.10 mm

CAUTION: Maximum press force: 15 kN.

Install the shims and bearing inner races into the clutch side of the crankcase.

Heat the crankcase area to approximately 80°C using a heat gun.
Cool the inner bearing races using a temperature reducing spray.
1. Install measuring shims.
2. Install the inner bearing rings.
Install the inner bearing rings:
primary shaft using special tool 204-017 (14-010)
secondary shaft using special tool 205-075 (15-036)
differential using special tool 204-050 (14-024)

NOTE: Do not apply oil to tapered roller bearings that are to be reused. Install new tapered roller bearings (untreated).

Insert the primary and secondary shafts into the gearbox housing.

Engage fourth gear.
Assemble the primary and secondary shafts and insert them together into the gearbox housing.

NOTE: Do not apply oil to tapered roller bearings that are to be reused. Install new tapered roller bearings (untreated).

Insert differential (1.8 Endura-DI shown).

NOTE: Check that the mating surface is clean.

Install the crankcase section (clutch side).

Install the special tool together with the longest bolt onto the transmission housing flange.

9. Install the crankcase section (clutch side). Tighten the 16 flange bolts evenly.

10. Install the special tool.

Place the measuring plunger against the fourth gear.

11. Prepare the input shaft for measurements.

Rotate the input shaft back and forth approximately 20 times to allow the bearings to settle into a stable position.

12. Install the dial indicator.

1. Attach a steel plate (such as 303-435-11 (21-146C)) to the gearbox.
2. Install the tripod with the magnetic base of the dial indicator.
3. Set the dial indicator to "0".

13.

NOTE: Perform the steps in the previous step and this step three times and calculate the average.

Measure the input shaft axial clearance.

1. Raise the input shaft using the assembly key.
2. Write down the result (for example, 0.22 mm).
Example: 0.22 mm + 0.23 mm + 0.21 mm, divided by 3 = 0.22 mm.

14. Prepare the secondary shaft for measurements.

Rotate the secondary shaft back and forth 20 times to allow the bearings to settle into a stable position (see previous point).
Install the dial indicator.
Set the dial indicator to "0".

15.

NOTE: Perform this and the next steps three times and calculate the average.

Measure the secondary shaft axial clearance.

Raise the secondary shaft using a wheel wrench and record the result, e.g. 0.32 mm.
Example: 0.32 mm + 0.34 mm + 0.33 mm, divided by 3 = 0.33 mm.

16. Prepare the differential for measurements.

Rotate the input shaft back and forth 20 times while simultaneously pressing down on the differential.
Install the dial indicator and set it to "0".

17.

NOTE: Perform this and the next steps three times and calculate the average.

Measure the differential end play

Raise the differential using a special tool and record the measurement, e.g. 0.34 mm
Example: 0.34 mm + 0.36 mm + 0.38 mm, divided by 3 = 0.36 mm.

18. Calculate the required thickness of the input shaft adjusting shim.

The required thickness of the gasket is 1.00 mm
Measured axial clearance (see previous paragraph) 0.22 mm.
Axial clearance - 0.05 mm
Required gasket thickness: 0.22 mm - 0.05 mm + 1.00 mm = 1.17 mm.

19. Calculate the required thickness of the secondary shaft adjusting shim.

The required gasket thickness is 1.00 mm.
Measured axial clearance (see previous paragraph) 0.33 mm.
Preload 0.13 mm.
Required gasket thickness: 1.00 mm + 0.33 mm + 0.13 mm = 1.46 mm.

20. Calculate the required differential gasket thickness.

The required gasket thickness is 1.10 mm.
Measured axial clearance (see previous point) 0.36 mm
Preload 0.33 mm.
Required gasket thickness: 1.10 mm + 0.36 mm + 0.33 mm = 1.79 mm.

21. Remove the inner bearing rings again.

Remove the inner bearing rings:
primary shaft
secondary shaft
differential

22. Install the adjusting shims and bearing inner races.

1. Install adjusting shims of the required thickness.
2. Install the inner bearing rings.
primary shaft
secondary shaft
differential

23. Install the reverse gear intermediate gear.

1. Lower thrust washer
2. Needle roller bearing
3. Reverse gear (smaller ring facing down)
4. Upper thrust washer
5. Retaining ring

24. Install the primary and secondary shafts together.

Lubricate the tapered roller bearings using gear oil.

25. Install the gear selector fork.

Move the fourth gear synchronizer clutch to neutral position.
Insert the 5th gear and reverse gear selection fork and move it to the side.

26. Install the third and fourth gear selection fork.

Move the 5th gear and reverse gear selection fork back.

27.

NOTE: When properly installed, the gear selector shafts will be at the same height.

Install the first and second gear selector forks and gear selector shafts.

28. Install the differential (1.8 Endura-DI shown).

1. Install the differential assembly.
2. Place a clean magnetic disk into the recess.

29. Apply sealant to the mating surface.

The sealing surfaces must be dry and free from oil. Apply the sealant evenly to the inside of the sealing surface (even bead 2 mm in diameter).

30.

NOTE: Do not turn the transmission over to tighten the case bolts.

Install the crankcase (clutch side).

Tighten the 16 flange bolts for 15 minutes, working in a crisscross pattern.

Cars manufactured up to 01.2000.

31.

NOTE: Make sure the transmission is in neutral (the gearshift lever and gear selector lever should be in the vertical position.

Install the gear selector mechanism.

The sealing surfaces must be dry and free from oil. Apply the sealant evenly to the outer side of the sealing surface (even bead 2 mm in diameter).
1. Bolt, M8x35 mm
2. Bolt, M8x85 mm

Cars manufactured since 02.2000.

32.

NOTE: Make sure the transmission is in neutral (the gearshift lever and gear selector lever should be in the vertical position.

Install the gear selector mechanism.

The sealing surfaces must be dry and free from oil. Apply the sealant evenly to the outer side of the sealing surface (even bead 2 mm in diameter).

33. Install the shift mechanism cover.

All cars

34. Measure the turning torque.

Engage fourth gear.
Measure the turning torque.
If the turning torque is too high, all measurements (to determine the required gasket thickness) should be repeated.

Diesel Engine Cars

35. Install the speedometer drive gear.

Insert the drive gear.
Insert the pin carefully.

Cars with 2.0L engine

36. Install the vehicle speed sensor (VSS).

All cars

37. Install the front axle oil seals.

38.

WARNING: Avoid contact with skin or eyes with brake fluid. If brake fluid contacts skin or eyes, rinse immediately with water. Failure to follow this instruction may result in injury.

CAUTION: Apply adhesive tape to the input shaft splines to prevent damage to the input shaft seal.

CAUTION: Do not lubricate the clutch slave cylinder.

NOTE: Install a new clutch slave cylinder.

Install the clutch slave cylinder using a new seal and slave cylinder sealant.

39. Remove the adhesive tape from the input shaft splines.

40. Apply a thin coat of high temperature grease to the input shaft splines.

Gearbox in block with driving axle — assembly

Special tool

Assembly

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