Manual Transmission Overhaul — general information (Transit 2)

1. Overhauling a manual transmission is a difficult job for a novice mechanic. It involves removing and installing many small parts. Numerous gaps must be accurately measured and, if necessary, adjusted with appropriate shims and clamps. Therefore, in the event of problems with the gearbox, the gearbox unit itself can be removed and reinstalled by the car owner, but a major overhaul of the gearbox should be entrusted to a specialist. Remanufactured transmissions can also be purchased from either a dealer or a parts dealer. In any case, the time and money invested in a major overhaul will almost certainly exceed the cost of the rebuilt unit.

2. Carrying out major repairs is not impossible for an inexperienced mechanic if special tools are available and the work is carried out thoughtfully, step by step, without losing sight of the smallest details.

3. To carry out major repairs, the following tools are required: pliers for removing retaining rings (compressing and decompressing), bearing puller, sliding hammer, punch set, dial play indicator and possibly a hydraulic press. You will also need a large vice or gearbox support.

Note: To carry out a major overhaul of the MT75 gearbox, a large number of additional special tools are required, and it is recommended that any work on this type of gearbox be entrusted to a specialist.

4. During the overhaul of the gearbox, carefully note how each part is removed, how it is located relative to other parts, and how it is secured.

5. Any information about which area of the gearbox is malfunctioning can help in repairing the removed gearbox. Some problems may be closely related to specific areas in the transmission, making it easier to locate the fault and easier to replace. Please refer to the section "Troubleshooting" at the beginning of this manual for information regarding possible sources of failure.

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