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

Transmission. Assembly

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
37steps
~277min
5/5difficulty
11special tools
010203040501813N·mlb·ft
Tightening torque found on this page
Done 0 of 37

Special Service Tools / General Equipment

100-002 (TOOL-4201-C)
Dial Indicator Holding Fixture
205-075
Installer, rear wheel hub seal
205-081A
Installer, differential bearing
205-115
Installer, pinion seal
TKIT-2000-F/FM/FLM
303-350 (T89P-6565-A)
Compressor, Valve Spring
TKIT-1990-LMX
TKIT-1989-F
TKIT-1989-FM
TKIT-1989-FLM
307-003 (T57L-500-B)
Holding Fixture, Transmission
307-680
Table Assembly (DPS6)
TKIT-2010D-FLM
TKIT-2010D-RYAD
308-847
Installer, Input Shaft Seal
308-849
Installer, shift shaft bushing
308-880
Installer, Output Shaft Seal
308-C217 (T94P-4451-BH)
Shim selection kit
TKIT-1994-LMH/MH2
TKIT-1994-FX/FMX/FLMX
Heat gun
Strike with a fist
Adhesive tape

Materials

Name Specification
Motorcraft® Gasket Making Device
TA-16		 WSK-M2G348-A5
Motorcraft® Dual Clutch Transmission Fluid
XT-11-DCTF		 WSS-M2C200-D2
Motorcraft® Silicone Brake Caliper Grease and Dielectric Compound
XG-3-A		 ESA-M1C200-A
ESE-M1C171-A
    1. Heat the clutch housing.
      Use the general equipment: heat gun.
    1. Cool the bearing cup.
    1. Using the special tool, install the bearing race into the clutch housing.
      Use the special service tool: 205-075 Installer, rear wheel hub seal.
  2. After the clutch housing has cooled, make sure the bearing cup is seated in the clutch housing.
    Use the special service tool: 205-075 Installer, rear wheel hub seal.
    1. Heat the transmission case.
      Use the general equipment: heat gun.
    1. Cool the bearing cup.
    1. Using the special tool, install the bearing cup into the transmission case.
      Use the special service tool: 205-075 Installer, rear wheel hub seal.
  4. After the transmission case has cooled, make sure the bearing cup is seated in the transmission case.
    Use the special service tool: 205-075 Installer, rear wheel hub seal.

  5. NOTICE: Surfaces must be thoroughly cleaned, or inaccurate preload measurement may cause differential bearing failure.

    Install the differential into the clutch housing, install the transmission case, and install every other bolt. Tighten the bolts in a crisscross sequence.
    Torque: 159 lb-in (18 N·m)
  6. Clean the differential assembly end face and mark it in one place. Install the special tool.
    Install the special service tool: 100-002 (TOOL-4201-C) Dial indicator holding fixture.
  7. Install the dial indicator at the marked location. Preload the dial indicator by 1 mm and zero it.
    Install the special service tool: 100-002 (TOOL-4201-C) Dial indicator holding fixture.
  8. Rotate the transmission case 180°.
    1. Using the special tool, press down on the differential.
      Use the special service tools: 303-350 (T89P-6565-A) Valve spring compressor, 308-C217 (T94P-4451-BH) Shim selection kit.
    1. Measure the differential end play and record the result.
      Use the special service tool: 100-002 (TOOL-4201-C) Dial indicator holding fixture.
    • Repeat this step 3 times and average the measurements. Example: 0.265 mm + 0.255 mm + 0.260 mm, divided by 3 = 0.260 mm.
    • Determine the differential adjusting shim thickness:
    • The determined differential end play is X mm.
    • The differential bearing preload is 0.14 mm.
    • Required adjusting shim thickness: X mm + 0.14 mm.
    • Determine the adjusting shim thickness.
    • If the determined adjusting shim thickness is not available, use the nearest adjusting shim thickness.
  11. Remove the special service tool: 100-002 (TOOL-4201-C) Dial indicator holding fixture.
  12. Remove the bolts, transmission case, and differential.
  13. Using a drift, drive the differential bearing cup out of the clutch housing.
    Use the general equipment: hammer
  14. Using the special tool, install the shift rod bushing into the clutch housing. Make sure the bushing is in the correct position as shown.
    Use the special service tool: 308-849 Installer, shift shaft bushing.
    1. Heat the clutch housing.
      Use the general equipment: heat gun.
    1. Cool the new input shaft roller bearing and install it into the clutch housing.
    1. Install the new adjusting shim.
    1. Cool the new differential bearing cup and install it into the clutch housing.
    1. Install the new lubrication funnel into the clutch housing.
    1. Cool the output shaft roller bearing and install it into the clutch housing.
  16. After the clutch housing has cooled, make sure the bearing is seated in the clutch housing.
    Use the special service tool: 205-081A Installer, differential bearing.
  17. After the clutch housing has cooled, make sure the bearing and bearing race are seated in the clutch housing.
    Use the special service tools: 205-075 Installer, rear wheel hub seal, 205-115 Installer, pinion seal.
  18. Using the special tools, install the shift mechanism bearing.
    Use the special service tool: 308-849 Installer, shift shaft bushing.
    Material: Motorcraft® Dual Clutch Transmission Fluid / XT-11-QDC (WSS-M2C200-D2)
  19. Using the special tool, install the shift rod bushing in the transaxle case. Make sure the bushing is in the correct position as shown.
    Use the special service tool: 308-849 Shift Rod Bushing Installer.
  20. Install the lubrication tube and magnet into the transmission case.
    Material: Motorcraft® Silicone Brake Caliper Grease and Dielectric Compound / XG-3-A (ESA-M1C200-A) (ESE-M1C171-A)
  21. Lubricate the output shaft roller bearing.
    Material: Motorcraft® Silicone Brake Caliper Grease and Dielectric Compound / XG-3-A (ESA-M1C200-A) (ESE-M1C171-A)
  22. Lubricate the bearings and install the differential.
    Material: Motorcraft® Dual Clutch Transmission Fluid / XT-11-QDC (WSS-M2C200-D2)
    1. Set the differential aside.

    1. NOTICE: Be careful not to damage the roller bearing when installing the reverse idler gear.

      Lubricate and install the reverse idler gear.
      Material: Motorcraft® Dual Clutch Transmission Fluid / XT-11-QDC (WSS-M2C200-D2)
  24. Assemble the input shaft, countershaft and shift forks.
    1. Lubricate the input shaft bearing and the shift rail bushing.
      Material: Motorcraft® Dual Clutch Transmission Fluid / XT-11-QDC (WSS-M2C200-D2)

    1. NOTICE: Be careful not to damage the bearings when installing the input shaft, countershaft and shift forks.

      Position the input shaft, countershaft and shift forks in the clutch housing.

    1. NOTICE: Make sure the output shaft is aligned with the bearing to avoid damaging the countershaft bearing.

      With the help of an assistant, align the output shaft with the countershaft roller bearing.
    1. Carefully lower the input shaft, countershaft and shift forks and install them into the clutch housing.
    1. Lubricate the input shaft and the output shaft rear bearings.
      Material: Motorcraft® Dual Clutch Transmission Fluid / XT-11-QDC (WSS-M2C200-D2)
    1. Lubricate the reverse synchronizer sleeve blocker rings with transmission fluid and install them so that they engage the synchronizer hub, as shown in the illustration.
    1. Install the reverse synchronizer sleeve and the reverse idler shift fork.
      Material: Motorcraft® Dual Clutch Transmission Fluid / XT-11-QDC (WSS-M2C200-D2)
    1. Install the special service tools.
      Install the special service tool: 307-680 Table, Assembly (DPS6).
    1. Apply flange sealant to the clutch housing.
      Material: Motorcraft® Gasket Maker / TA-16 (WSK-M2G348-A5)

    1. NOTICE: Make sure new bolts are installed.

      Install the transmission case and install new bolts.
      Torque:
      Stage 1: 159 lb-in (18 N·m)
      Stage 2: 90°
    1. Remove the special service tool: 307-680 Table, Assembly (DPS6).

    1. NOTICE: Make sure new bolts are installed.

      Install new transmission case bolts.
      Torque:
      Stage 1: 159 lb-in (18 N·m)
      Stage 2: 90°

    1. NOTICE: Make sure new bolts are installed.

      Apply sealer to the underside of the bolts.
      Material: Motorcraft® Gasket Maker / TA-16 (WSK-M2G348-A5)
    1. Install new bolts.
      Torque: 177 lb-in (20 N·m)
    1. Install a new seal on the transmission case.
    1. Using the special tool, install a new seal in the transaxle case.
      Use the special service tool: 308-880 Driveshaft Seal Installer.
  30. Make sure the transmission is in neutral.
  31. Lubricate and install the O-ring.
    Material: Motorcraft® Dual Clutch Transmission Fluid / XT-11-QDC (WSS-M2C200-D2)
    1. Make sure the shift forks are in the neutral (N) position.

    1. NOTICE: Make sure no components are binding.

      Install the shift selector mechanism.
    1. Install the bolts.
      Torque: 18 lb-ft (24 N·m)
  33. Install the shift cable brackets and bolts.
    Torque: 18 lb-ft (24 N·m)

    1. NOTICE: Use adhesive tape to cover the input shaft splines to prevent damage to the input shaft seal.

      Wrap the input shaft with tape.
      Use the general equipment: adhesive tape
    1. Install a new seal on the input shaft.
    1. Using the special tool, install the input shaft seal.
      Use the special service tool: 308-847 Installer, Input Shaft Seal.
    1. Remove and discard the tape.
    1. Install new bolts.
      Torque:
      Stage 1: 159 lb-in (18 N·m)
      Stage 2: 90°
    1. Install a new left axle shaft seal into the transaxle.
    1. Using the special tool, install the left axle shaft seal.
      Use the special service tool: 308-880 Installer, Driveshaft Seal.
    1. Remove the special service tool: 307-003 (T57L-500-B) Holding Fixture, Transmission.
  36. Install the slave cylinder and 2 bolts.
    Torque: 89 lb-in (10 N·m)
  37. Install the roll restrictor bracket.
    Torque: 35 lb-ft (48 N·m)

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