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

Output Shaft. Disassembly and Assembly of Sub-assemblies

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
22steps
~147min
5/5difficulty
3special tools
0408012016020011081N·mlb·ft
Tightening torque found on this page
Done 0 of 22

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
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

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

    Install the output shaft in a vise. Secure the output shaft on the flat surfaces.
    Use the general equipment: vise
    Use the general equipment: vise jaw protectors
  2. Heat the bolt to melt the Loctite®, then remove and discard the rear bearing bolt.
    Use common equipment: heat gun.
  3. Using the special tools, remove the output shaft rear bearing.
    Use the special service tool: 211-014 Puller, steering wheel.
  4. Remove the 6th gear.
    Use the special service tool: 205-D015. (D80L-630-4) Step plate.
    Use the general equipment: hydraulic press
    Use the general equipment: bearing separator
  5. Remove the 5th and 4th gears.
    Use the general equipment: bearing separator
    Use the general equipment: hydraulic press
    1. Move the 1-2 synchronizer hub sleeve down to the 1st gear position.
    1. Remove the 2nd and 3rd gears.
      Use the general equipment: bearing separator
      Use the general equipment: hydraulic press
  7. Remove the 2nd gear synchronizer assembly.
    1. Remove the 1-2 synchronizer sleeve.
    1. Remove the clips.
  9. Remove the 1-2 synchronizer hub.
    Use the general equipment: hydraulic press
  10. Remove the 1st gear, release the roller bearing retainer and remove the roller bearing. Remove the thrust washer.

ASSEMBLY

  1. Install the thrust washer. Install the roller bearing and connect the roller bearing cage. Install the 1st gear.
    Material: Motorcraft® Dual Clutch Transmission Fluid / XT-11-QDC (WSS-M2C200-D2)
  2. Lubricate the 1st gear synchronizer with transmission fluid and install the synchronizer.
    Material: Motorcraft® Dual Clutch Transmission Fluid / XT-11-QDC (WSS-M2C200-D2)
  3. Using the special tools, install the 1st and 2nd gears. Synchronizer sleeve. Align the hub with the 1st gear synchronizer.
    Use the special service tool: 205-D015. (D80L-630-4) Step plate.
    Use the general equipment: hydraulic press
    1. Install the 1-2 synchronizer sleeve.
    1. Lubricate the 1-2 synchronizer sleeve. Dip the detents in transmission fluid and install them so that they engage the 1-2 synchronizer hub, as shown in the illustration.
      Material: Motorcraft® Dual Clutch Transmission Fluid / XT-11-QDC (WSS-M2C200-D2)
    1. Install the 1-2 synchronizer hub snap ring.
    1. Lubricate the parts with transmission fluid and install the 2nd gear synchronizer assembly.
      Material: Motorcraft® Dual Clutch Transmission Fluid / XT-11-QDC (WSS-M2C200-D2)
    1. Install the 2nd gear.
      Material: Motorcraft® Dual Clutch Transmission Fluid / XT-11-QDC (WSS-M2C200-D2)
  6. Using the special tools, install the 3rd gear.
    Use the special service tool: 205-199 (T83T-3132-A1) Installer, spindle/axle.
    Use the general equipment: hydraulic press
  7. Using the special tools, install the 4th gear.
    Use the special service tool: 205-199 (T83T-3132-A1) Installer, spindle/axle.
    Use the general equipment: hydraulic press
  8. Using the special tools, install the 5th gear.
    Use the special service tool: 205-199 (T83T-3132-A1) Installer, spindle/axle.
    Use the general equipment: hydraulic press
  9. Using the special tools, install the 6th gear.
    Use the special service tool: 205-199 (T83T-3132-A1) Installer, spindle/axle.
    Use the general equipment: hydraulic press
  10. Using the special tool, install the rear bearing.
    Use the special service tool: 205-D015. (D80L-630-4) Step plate.
    Use the general equipment: hydraulic press

  11. NOTICE: Use vise jaw protectors to protect the jaws.

    Install the output shaft in a vise. Secure the output shaft on the flat surfaces.
    Use the general equipment: vise
    Use the general equipment: vise jaw protectors
  12. Install a new rear bearing bolt.
    Torque: 81 lb-ft (110 N·m)

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