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Home >> Ford >> 2003 >> Focus SVT, 2D Hatchback >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 10 (Manual Transmission-MTX75) >> Disassembly And Assembly Of Subassemblies >> Input Shaft >> Assembly

Input Shaft: Assembly

WARNING: This page is about a different variant/trim than selected.
    NOTE: Do not oil taper roller bearings which are to be used again. New taper roller bearings can be installed without any treatment.
    NOTE: Using a suitable press, install the gear wheels.
  1. Carefully clean and check all sliding parts and lubricate them with clean manual transmission fluid before assembly.
  2. Using a length of suitable tube, install the clutch housing roller bearing.
    Fig 1: Installing Clutch Housing Roller Bearing
    G01613525Courtesy of FORD MOTOR CO.
    3. NOTE: Do not oil taper roller bearings which are to be used again. New taper roller bearings can be installed without any treatment.
  3. Install the third gear wheel.
    1. Install the needle roller bearing.
    2. Install the gear wheel.
    3. Install the synchronizer ring.
      Fig 2: Installing Third Gear Wheel
      G01613526Courtesy of FORD MOTOR CO.
  4. Assemble the third and fourth gear synchronizer.
    1. Install the compression springs.
    2. Install the synchronizer bar and detent balls by pressing against the spring pressure.
    3. Install the selector ring the right way round and slide it on.
      Fig 3: Assembling Third And Fourth Gear Synchronizer
      G01613527Courtesy of FORD MOTOR CO.
    5. NOTE: Install the synchronizer hub with the large collar facing outwards and the annular groove facing the small collar.
    Fig 4: Identifying Installation Position Of Synchronizer Assembly
    G01613528Courtesy of FORD MOTOR CO.
  5. Installation position of the synchronizer assembly shown.
    6. NOTE: Install the synchronizer hub with the large collar facing outwards.
    NOTE: Install a new snap ring.
    NOTE: The snap ring thickness is 2.5 mm.
  6. Install the complete third and fourth gear synchronizer assembly.
    1. Install the synchronizer assembly.
    2. Install the snap ring.
      Fig 5: Installing Complete Third And Fourth Gear Synchronizer Assembly
      G01613529Courtesy of FORD MOTOR CO.
  7. Install the fourth gear wheel.
    1. Install the synchronizer ring.
    2. Install the needle roller bearing.
    3. Install the gear wheel.
      Fig 6: Installing Fourth Gear Wheel
      G01613530Courtesy of FORD MOTOR CO.
    8. NOTE: Install a new snap ring.
  8. Press on the fifth gear wheel.
    • Using a length of suitable tube, press on the fifth gear wheel.
    • Install the snap ring.
      Fig 7: Pressing Fifth Gear Wheel
      G01613531Courtesy of FORD MOTOR CO.
  9. Using a length of suitable tube, install the transaxle housing roller bearing.
    Fig 8: Installing Transaxle Housing Roller Bearing
    G01613532Courtesy of FORD MOTOR CO.
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