Ford Fiesta Quiz
Manual Transmission, Clutch, Transfer Case and Power Transfer Unit

Input Shaft. Disassembly and Assembly of Components

In this manual: Manual Transmission, Clutch, Transfer Case and Power Transfer Unit
Service Information — 27Suspension — 48Transmission — 9Brake System — 52Steering — 21Engine — 140Manual Transmission, Clutch, Transfer Case and Power Transfer Unit — 48Exhaust System — 6Fuel System — 21Climate Control System — 58Instrumentation and Warning Systems — 26Battery and Charging System — 20Infotainment Systems — 41Lighting — 29Power Distribution — 11Electronic Function Group — 30Body and Paint — 275Frame and Mounting — 3
23steps
~158min
5/5difficulty
4special tools
0408012016020011081N·mlb·ft
Tightening torque found on this page
Done 0 of 23

Special Service Tools / General Equipment

205-199 (T83T-3132-A1)
Spindle/Axle Installer
T83-4000-A
TKIT-1983-F
TKIT-1983-FLM
TKIT-1983-FX
205-D015 (D80L-630-4)
Step Plate
211-014
Puller, Steering Wheel
307-679
Installer, Countershaft Needle Bearing
TKIT-2010D-FLM
TKIT-2010D-RYD
Hydraulic Press
Heat gun
Bearing Separator
vise
Vise Jaw Protectors

Materials

Name Specification
Motorcraft® Dual Clutch Transmission Fluid
XT-11-DCTF		 WSS-M2C200-D2

DISASSEMBLY

    • Remove and discard the snap ring.
    • Using the special tools, remove and discard the front bearing.
      Use the general equipment: hydraulic press
      Use the general equipment: bearing separator

  2. NOTICE: Use protective vise jaws, otherwise the splines may be damaged.

    1. Install the input shaft in a vise.
      Use the general equipment: vise
    1. Use vise jaw protectors.
      Use the general equipment: vise jaw protectors
  3. Heat the bolt to melt the Loctite®, then remove and discard the rear bearing bolt.
    Use common equipment: heat gun.
  4. Using special tools, remove and discard the rear bearing.
    Use special service tool: 211-014 Puller, Steering Wheel.
  5. Remove the 6th gear, the 6th gear synchronizer assembly, and remove and discard the 5-6 synchronizer hub snap ring.
  6. Remove the 5-6 synchronizer sleeve and the 3 detents.
  7. Using special tools, remove the 5-6 synchronizer hub, the 5th gear synchronizer assembly and 5th gear.
    Use common equipment: bearing separator
    Use common equipment: hydraulic press
  8. Remove the 4th gear detent, 4th gear and the 3-4 synchronizer assembly. Remove and discard the 3-4 synchronizer hub snap ring.
  9. Remove the 3-4 synchronizer sleeve and detents.
  10. Using special tools, remove the 3-4 synchronizer hub, the 3rd gear synchronizer assembly and 3rd gear.
    Use common equipment: bearing separator
    Use common equipment: hydraulic press
  11. Remove the 3rd gear bearing.

ASSEMBLY

  1. NOTICE: Use protective vise jaws, otherwise the splines may be damaged.

    1. Install the input shaft in a vise.
      Use the general equipment: vise
    1. Use vise jaw protectors.
      Use the general equipment: vise jaw protectors
  2. Lubricate the components with transmission fluid and install the 3rd gear bearing, 3rd gear and the 3rd gear synchronizer assembly.
    Material: Motorcraft® Dual Clutch Transmission Fluid / XT-11-DCTF (WSS-M2C200-D2)
  3. Using the special service tools, install the 3-4 synchronizer hub.
    Use the special service tool: 205-199 (T83T-3132-A1) Shaft/Axle Installer.
    1. Install the 3-4 synchronizer sleeve.
    1. Lubricate the 3-4 synchronizer sleeve blocker rings with transmission fluid and install them so that they engage the 3-4 synchronizer hub, as shown in the illustration.
      Material: Motorcraft® Dual Clutch Transmission Fluid / XT-11-QDC (WSS-M2C200-D2)
    1. Install the 3-4 synchronizer hub snap ring.
    1. Lubricate the components with transmission fluid and install the 4th gear synchronizer assembly and the 4th gear.
      Material: Motorcraft® Dual Clutch Transmission Fluid / XT-11-QDC (WSS-M2C200-D2)
    1. Install the 4th gear retainer.
    1. Lubricate the components with transmission fluid and install the 5th gear and the 5th gear synchronizer assembly.
      Material: Motorcraft® Dual Clutch Transmission Fluid / XT-11-QDC (WSS-M2C200-D2)
  7. Using the special service tools, install the 5-6 synchronizer hub.
    Use the special service tool: 205-199 (T83T-3132-A1) Shaft/Axle Installer.
    Use the general equipment: hydraulic press
    1. Install the fifth-sixth synchronizer sleeve.
    1. Lubricate the 5-6 synchronizer sleeve blocker rings with transmission fluid and install them so that they engage the 5-6 synchronizer hub, as shown in the illustration.
      Material: Motorcraft® Dual Clutch Transmission Fluid / XT-11-QDC (WSS-M2C200-D2)
    1. Install a new fifth-sixth synchronizer hub snap ring.
    1. Lubricate the components with transmission fluid and install the 6th gear synchronizer assembly and the 6th gear.
      Material: Motorcraft® Dual Clutch Transmission Fluid / XT-11-QDC (WSS-M2C200-D2)
  10. Using the special tools, install the rear bearing.
    Use the special service tool: 205-D015. (D80L-630-4) Step plate.
    Use the general equipment: hydraulic press
  11. Install a new rear bearing bolt.
    Torque: 81 lb-ft (110 N·m)
    1. Install the front bearing on the input shaft.
    1. Using the special tools, install the front bearing.
      Use the special service tool: 307-679 Installer, countershaft needle bearing.
      Use the general equipment: hydraulic press
    1. Install a new retaining ring.

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