Manual Transmission Repair (Mondeo 1 and 2)

1. Manual transmission repair is a difficult job for a DIYer. The repair requires removing and reinstalling many small parts. Numerous gaps must be accurately measured and, if necessary, changed using selective spacers, spacers, and spring washers. Therefore, if there are problems with the transmission, even a DIYer can remove and install it, but it is better to entrust the repair to a specialist. You can try to get a rebuilt transmission; in any case, the time and money spent on repairs will almost certainly exceed the cost of the rebuilt unit.

2. However, this does not mean that an inexperienced mechanic at home cannot restore the transmission. To do this, you need to have a set of special tools and work slowly, step by step, so as not to miss anything important.

3. Tools and fixtures required for repair include: pliers for removing and installing inner and outer snap rings, a bearing puller, an impact puller, a set of drifts, a dial indicator, and possibly a hydraulic press. A large, sturdy workbench with a vice or a transmission mounting stand is also required.

4. As you disassemble the transmission, take careful notes on how each part comes off, where it fits relative to other parts, and how it is held in place (see Fig. 9.4, a-d).









5. Before removing the transmission for repair, it is a good idea to have some idea of where in the transmission the problem is located. Some problems may be associated with specific components of the transmission, making it easier to check and replace parts. Information on possible causes of failures is provided in the Troubleshooting section at the end of this book.

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