Manual Transmission/

Transaxle Repair

36 - Manual Transmission & Drivetrain

Student Guide
FCS-14836-REF
Course Code: 36S12T0
August 2007

Ford Customer Service Division

Technical Training

Blank

IMPORTANT SAFETY NOTICE

Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles,
as well as the personal safety of the individual doing the work. This manual provides general directions for accomplishing
service and repair work with tested, effective techniques. Following them will help assure reliability.
There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the
individual doing the work. This manual cannot possibly anticipate all such variations and provide advice or cautions as to each.
Accordingly, anyone who departs from instructions provided in this manual must first establish that he compromises neither
his personal safety nor the vehicle integrity by his choice of methods, tools or parts.
As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each one is there for a
specific purpose. NOTES give you added information that will help you to complete a particular procedure. CAUTIONS are
given to prevent you from making an error that could damage the vehicle. WARNINGS remind you to be especially careful
in those areas where carelessness can cause personal injury. The following list contains some general WARNINGS that you
should follow when you work on a vehicle.
Always wear safety glasses for eye protection.
Use safety stands whenever a procedure requires you
to be under the vehicle.
Be sure that the ignition switch is always in the OFF
position, unless otherwise required by the procedure.
Set the parking brake when working on the vehicle. If you
have an automatic transmission, set it in PARK unless
instructed otherwise for a specific service operation. If
you have a manual transmission it should be in REVERSE
(engine OFF) or NEUTRAL (engine ON) unless instructed
otherwise for a specific service operation.
Operate the engine only in a well-ventilated area to avoid
the danger of carbon monoxide.
Keep yourself and your clothing away from moving parts
when the engine is running, especially the fan and belts.

To help prevent serious burns, avoid contact with hot

metal parts such as the radiator, exhaust manifold, tail
pipe, catalytic converter and muffler.
Do not smoke while working on the vehicle.
To help avoid injury, always remove rings, watches,
loose hanging jewelry, and loose clothing before beginning to work on a vehicle. Tie long hair securely behind
your head.
Keep hands and other objects clear of the radiator fan
blades. Electric cooling fans can start to operate at any
time by an increase in underhood temperatures, even
though the ignition is in the OFF position. Therefore,
care should be taken to ensure that the electric cooling
fan is completely disconnected when working under the
hood.

The recommendations and suggestions contained in this manual are made to assist the dealer in improving his dealership parts
and/or service department operations. These recommendations and suggestions do not supersede or override the provisions of
the Warranty and Policy Manual, and in any cases where there may be a conflict, the provisions of the Warranty and Policy Manual
shall govern.
The descriptions, testing procedures, and specifications in this handbook were in effect at the time the handbook was
approved for printing. Ford Motor Company reserves the right to discontinue models at any time, or change specifications,
design, or testing procedures without notice and without incurring obligation. Any reference to brand names in this manual
is intended merely as an example of the types of tools, lubricants, materials, etc. recommended for use. Equivalents, if
available, may be used. The right is reserved to make changes at any time without notice.

DANGER: Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure to excessive amounts of dust may be a potential cancer and lung disease
hazard. Exposure may also cause irritation to skin, eyes, and respiratory tract, may cause allergic reactions, and/or may lead to other
chronic health effects.
Do not breathe dust. Do not use compressed air to blow dust from storage containers or friction components. A high-efficiency
(HEPA) vacuum cleaner should be used carefully to remove dust. Adherent dust should be removed with a damp rag.
If inhaled, remove to fresh air. If irritation persists, seek medical attention or advice.
If dust gets in eyes, irrigate under eyelids with water for 15 minutes and seek medical attention.

Copyright 2007 Ford Motor Company

Produced and Coodinated by

Technical Support Operations
Ford Customer Service Division
August 2007

CUSTOMER EXPECTATIONS

Customer Expectations: Service

1. Make it convenient to have my vehicle

serviced at your dealership.

2. The Service Advisor should demonstrate

a genuine concern for my service needs.

3. Fix it right the first time, on time.

4. Complete servicing my vehicle in a
timely and professional manner.

5. Provide me with a clear and thorough

explanation of the service performed.

6. Call me within a reasonable amount of

time after my service visit to ensure that
I'm completely satisfied.

7. Be responsive to questions or concerns

that I bring to your attention.

Expectation #3
Fix It Right the First Time, on Time.
Both service advisors and technicians are important players when it comes to Expectation #3.
Why
Customers tell us Fixing It Right the First Time, on Time is one of the reasons they would
decide to return to a dealer to buy a vehicle and get their vehicles serviced.
Technician Training
It is our goal to help the technician acquire all of the skills and knowledge necessary to
Fix it Right the First Time, on Time. We refer to this as competency.
Technicians Role
Acquire the skills and knowledge for competency in your specialty via:
STST
New Model
Web-Based
Web-Based
Instructor Led
Instructor Led
The Benefits
The successful implementation of expectations means:
Satisfied customers
Repeat vehicle sales
Repeat service sales
Recognition that Ford and Lincoln/Mercury technicians are the Best in the Business

MANUAL TRANSMISSION/TRANSAXLE REPAIR

TABLE OF CONTENTS

INTRODUCTION ................................................................................................ INTRO - 1

Manual Transmission/Transaxle Repair .................................................................................... Intro - 2
Course Description .............................................................................................................. Intro - 2
Course Requirements .......................................................................................................... Intro - 3
Course Objectives ............................................................................................................... Intro - 3
Course Agenda ................................................................................................................... Intro - 3

LESSON ONE ............................................................................................................ 1 - 1

Prerequisite Review .......................................................................................................................1 - 2
Theory and Operation Questions ..............................................................................................1 - 2
Diagnosis Questions ................................................................................................................1 - 3

LESSON ONE WORKSTATIONS ................................................................................ 1 - 7

Workstation 1A T5OD Disassembly ...............................................................................................1 - 8
Workstation 2A Disassembly and Assembly of T5OD Transmission Subassemblies...................1 - 10
Workstation 3A T5OD Transmission Assembly ............................................................................1 - 12

LESSON TWO ............................................................................................................ 2 - 1

Workstation 1B Clutch Diagnosis and Service ...............................................................................2 - 2
Workstation 2B MTX-75 Transaxle Disassembly............................................................................2 - 4
Workstation 3B MTX-75 Transaxle Assembly ................................................................................2 - 6

Manual Transmission/Transaxle Repair

TOC - i

August 2007

MANUAL TRANSMISSION/TRANSAXLE REPAIR

Manual Transmission/Transaxle Repair

TOC - ii

TABLE OF CONTENTS

August 2007

MANUAL TRANSMISSION/TRANSAXLE REPAIR

INTRODUCTION

INTRODUCTION

Manual Transmission/Transaxle Repair

Intro - 1

August 2007

MANUAL TRANSMISSION/TRANSAXLE REPAIR

INTRODUCTION

MANUAL TRANSMISSION/TRANSAXLE REPAIR

Course Description

T5OD Transmission (Left) and MTX-75 Transaxle (Right)

This instructor-led course is part of the Ford Manual Transmission and Drivetrain curriculum. It is a two-day
course facilitated by an instructor. This course is designed to provide hands-on opportunities for technicians to
learn and improve their skills using tools and equipment, and to apply knowledge learned in prerequisite courses.
Each day, you will have multiple opportunities to practice selected skills. The results of your work are recorded
on worksheets.

Manual Transmission/Transaxle Repair

Intro - 2

August 2007

MANUAL TRANSMISSION/TRANSAXLE REPAIR

INTRODUCTION

Course Requirements
Each technician attending this course is required to pass a combination of hands-on and written
evaluations. These are administered after all lectures, demonstrations and/or practice sessions have been
completed.


The hands-on evaluation is a pass/fail type. It is conducted with exercises in manual transmission and
transaxle assembly, and covers:

selected end play measurements to be made during assembly

service publication navigation

selected special tool usage

To pass the course, you must demonstrate 100% mastery of the skills covered in the Hands-On Post-Test
exercises AND you must correctly answer at least 80% of the Written Post-Test questions.

Course Objectives
Upon successful completion of this course, you will be able to:


Explain common manual transmission and transaxle system diagnostic procedures.

Perform manual transmission and transaxle repairs.

Perform clutch system diagnosis and service.

Course Agenda


Introductions

Prerequisite Review

WORKSTATIONS

Rotation 1: T5OD Transmission Disassembly, Subassemblies and Assembly

Rotation 2: Clutch Diagnosis and Service; MTX-75 Transaxle Disassembly and Assembly

Workstations Review

Hands-On and Written Evaluations

Manual Transmission/Transaxle Repair

Intro - 3

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MANUAL TRANSMISSION/TRANSAXLE REPAIR

INTRODUCTION

NOTES:

Manual Transmission/Transaxle Repair

Intro - 4

August 2007

LESSON ONE

PREREQUISITE REVIEW

LESSON ONE

Manual Transmission/Transaxle Repair

1-1

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LESSON ONE

PREREQUISITE REVIEW

PREREQUISITE REVIEW
DIRECTIONS: Answer the following questions on manual transmissions, transaxles and clutches.
Questions may be related to theory, operation, diagnosis and service. These will be reviewed in class.

Theory and Operation Questions

1. In a RWD manual transmission, in which direction do the following shafts rotate, relative to the engine, with
the transmission moving in a forward gear?
(Circle one.)
Input shaft:

SAME AS ENGINE ROTATION

OPPOSITE TO ENGINE ROTATION

Countershaft:

SAME AS ENGINE ROTATION

OPPOSITE TO ENGINE ROTATION

Output shaft:

SAME AS ENGINE ROTATION

OPPOSITE TO ENGINE ROTATION

2. Number the following steps 1 through 4, to show the order of the powerflow through a RWD
transmission in Reverse gear.
_______

Countershaft/gear

_______

Output shaft gear

_______

Input shaft gear

_______

Idler gear

3. List some of the reasons a synchronizer is used in a manual transmission or transaxle:

_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________

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August 2007

LESSON ONE

PREREQUISITE REVIEW

4. Dampening springs in the clutch disc or flywheel accomplish all of the following EXCEPT:
A. Reduce chatter/shudder during clutch engagement
B. Reduce clutch slippage
C. Reduce NVH
D. Absorb power pulses from the engine

5. What components in the manual transaxle differential assembly allow for wheel speed differences during
cornering?
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________

Diagnosis Questions
6. A damaged shift interlock can cause which of the following concerns? (Circle all that apply.)
Locked out of certain gears
Two gears engaged at the same time
Gear clash during shifting
Transmission locked in one gear
Chattering noise in forward gears

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August 2007

LESSON ONE

PREREQUISITE REVIEW

7. On a rear-wheel drive vehicle, a squealing noise is present when the clutch pedal is depressed and the vehicle
is stopped with the transmission in gear. What is the likely cause?
A. Clutch release bearing
B. Pilot bearing
C. Input shaft bearing
D. Countershaft bearing

8. A whining noise is present only while driving with the manual transmission in 2nd gear. List some
components that could possibly cause this concern:
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________

9. A whining noise is present while driving with the manual transmission in any gear except direct drive. Which
of the following could cause this concern?
A. Pilot bearing
B. Countershaft bearings
C. Input shaft bearing
D. Pocket (input) thrust bearing

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LESSON ONE

PREREQUISITE REVIEW

10. A customer complains of a grinding condition that exists whenever the T5OD manual transmission is shifted
into Reverse.
Technician A says that the reverse brake ring assembly could cause this concern.
Technician B says that the driver may be shifting into Reverse while the vehicle is moving.
Who is correct?
A. Technician A
B. Technician B
C. Both Technicians
D. Neither Technician

11. While road testing a vehicle with a manual transmission, you verify a customer concern that the transmission
jumps out of gear. List the possible causes of this concern:
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________

12. What condition could cause accelerated wear on a shift fork or synchronizer assembly?
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________

Manual Transmission/Transaxle Repair

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August 2007

LESSON ONE

PREREQUISITE REVIEW

13. What steps are required to properly test for a slipping clutch?
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
What is the condition if the engine:
stalls within 5 seconds after clutch is fully engaged? ________________________________________
does not stall when clutch is fully engaged? _____________________________________________

14. During removal of a manual transaxle, why is a special puller required to remove and install the halfshaft
assembly from the wheel ends?
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________

15. If a RWD transmission has worn countershaft bearings, a whining or growling noise would become quieter in
which gear range?
A. Reduction
B. Direct drive
C. Overdrive
D. Reverse

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LESSON ONE

WORKSTATIONS

LESSON ONE
WORKSTATIONS
Workstation:

Summary:

1A

Students use the Workshop Manual and required special tools to disassemble a T5OD
transmission and answer related questions in the worksheet.

2A

Students use the Workshop Manual and required special tools to disassemble and assemble
selected T5OD transmission subassemblies and answer related questions in the worksheet.

3A

Students use the Workshop Manual and required special tools to assemble a T5OD
transmission, perform all end play measurements, and answer related questions in the
worksheet.

Manual Transmission/Transaxle Repair

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LESSON ONE

WORKSTATION 1A

WORKSTATION 1A
T5OD DISASSEMBLY
DIRECTIONS: Complete Workstation 1A at the bench workstation, using the T5OD transmission, available
hand tools and special service tools, and Workshop Manual.
SUMMARY: For this activity, you will disassemble a T5OD transmission down to its major subassemblies and
perform any necessary inspections required by the Workshop Manual.


Follow the Mustang Workshop Manual, Section 308-03A, to disassemble the T5OD transmission to its major
subassemblies. (Use the appropriate model year Workshop Manual for the transmission you have in class.)

As you perform the disassembly procedures, pay attention to the following questions related to key steps.

1. Can the clutch slave cylinder retaining clip be reused? Why or why not? (Applicable to 2005 MY or newer
T5OD transmissions.)
_______________________________________________________________________________________
2. Upon mounting the transmission to the holding fixture, in what position must the transmission gearshift lever
be placed?
_______________________________________________________________________________________
3. The gearshift offset lever cannot be removed while the transmission extension housing is bolted in place.
Why?
_______________________________________________________________________________________
_______________________________________________________________________________________
4. Why are two of the transmission cover bolts larger than the others?
_______________________________________________________________________________________
5. Why is it important to NOT pry against machined sealing surfaces?
_______________________________________________________________________________________
_______________________________________________________________________________________
6. Why is it important to support the reverse gear shift rail with a block of wood?
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________

Follow Worksheet 2A to disassemble and assemble some of the above subassemblies.

Continued on next page.

Manual Transmission/Transaxle Repair

1-8

August 2007

LESSON ONE

WORKSTATION 1A

7. Why does the Workshop Manual tell you to note the position of the reverse gearshift lever/shift fork assembly
and reverse positioning spring?
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
8. Can the countershaft bearing retainer be reused? Why or why not?
_______________________________________________________________________________________
_______________________________________________________________________________________
9. What is the purpose of using tool 204-069 and 205-D064 during disassembly?
_______________________________________________________________________________________
10. Upon completion of the disassembly procedures in the Workshop Manual, what subassemblies are left?
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________

Manual Transmission/Transaxle Repair

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August 2007

LESSON ONE

WORKSTATION 2A

WORKSTATION 2A
DISASSEMBLY AND ASSEMBLY OF T5OD TRANSMISSION SUBASSEMBLIES
DIRECTIONS: Complete Workstation 2A at the bench workstation, using the T5OD transmission, available
hand tools and special service tools, and Workshop Manual.
SUMMARY: For this activity, you will disassemble and assemble the input shaft, output shaft and one
synchronizer from a T5OD transmission and perform any necessary inspections required by the Workshop
Manual.


Follow the Mustang Workshop Manual, Section 308-03A, to disassemble and assemble the T5OD
transmission subassemblies. (Use the appropriate model year Workshop Manual for the transmission you
have in class.)

As you perform the disassembly and assembly procedures, pay attention to the following questions related to
key steps.

Input Shaft
1. Inspect the input shaft splines for wear or damage. Why is it important to do this?
_______________________________________________________________________________________
_______________________________________________________________________________________
2. For this activity, DO NOT remove the input shaft seal. If removed, could the input shaft seal be reused?
Why or why not?
_______________________________________________________________________________________
3. What condition would likely be present if the input shaft needle bearing and spacer are worn or scored?
_______________________________________________________________________________________
4. Are the selective shims initially installed during assembly of the T5OD input shaft subassembly? Why or
why not?
_______________________________________________________________________________________

Output Shaft
NOTE: During disassembly, inspect bearings, needle bearings, and gears for any signs of wear or damage.
5. Be sure to remove the ball under the inner race for the 1st speed gear before removing the 1st synchronizer
cones and blocking ring. What is the purpose of this ball?
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________

Continued on next page.

Manual Transmission/Transaxle Repair

1 - 10

August 2007

LESSON ONE

WORKSTATION 2A

Synchronizer
6. Before removing a synchronizer from the output shaft, use a feeler gauge to measure the wear gap clearance
between the synchronizer blocking ring and the clutching teeth on the gear. Enter the value below:
_______________________________________________________________________________________
If the gap is below __________ millimeters or __________ inches, replace the appropriate blocking ring.
7. Are synchronizer components interchangeable? Why or why not?
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
8. How are the springs for the synchro keys installed?
_______________________________________________________________________________________
_______________________________________________________________________________________
9. Why is proper clocking/timing of the synchronizer keys critical during assembly?
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________

NOTE: Assemble the synchronizer, install it on the Output Shaft and then finish assembly of the Output Shaft.

Manual Transmission/Transaxle Repair

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August 2007

LESSON ONE

WORKSTATION 3A

WORKSTATION 3A
T5OD TRANSMISSION ASSEMBLY
DIRECTIONS: Complete Workstation 3A at the bench workstation, using the T5OD transmission, available
hand tools and special service tools, and Workshop Manual.
SUMMARY: For this activity, you will assemble a T5OD transmission, performing any necessary measurements
and inspections required by the Workshop Manual.


Follow the Mustang Service Information, Section 308-03A, to assemble the T5OD transmission and perform
any necessary inspections and measurements. (Use the appropriate model year Workshop Manual for the
transmission you have in class.)

If adjustments are required, identify the correct size select-fit part that is needed.

1. What are the instructions for soaking the blocking rings prior to assembly?
_______________________________________________________________________________________
2. Use a new bearing retainer plate to obtain end play measurements. After gauging, install the original bearing
retainer plate. Using the dial indicator to measure countershaft bearing gear end play.
Your measurement: __________________________
Specification: __________________________________________________
What size shim is needed to bring the end play within specifications? __________________________
3. When installing the reverse idler gear and bushing in the T5OD case, the shift lever groove must face toward:
_______________________________________________________________________________________
4. How can you tell if the reverse positioning spring is installed correctly?
_______________________________________________________________________________________
5. When installing the input shaft bearing retainer, the notch on the circular mount MUST face _____________,
and the slot must face ________________.
6. How much silicone rubber sealant (TA-32) must be applied to the input shaft bearing retainer?
_______________________________________________________________________________________
7. What would be the result if too much sealant is applied?
_______________________________________________________________________________________
_______________________________________________________________________________________
8. To prevent component damage, the alignment tab on the reverse brake ring must align with:
_______________________________________________________________________________________
9. Using the dial indicator, measure output shaft end play.
Your measurement: ___________________________________________________
Specification:

___________________________________________________

What size shim is needed to bring the end play within specification? __________________________

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LESSON TWO

WORKSTATIONS

LESSON TWO
WORKSTATIONS
Workstation:

Summary:

1B

Students use the Workshop Manual, available components and a clutch system buck to
perform selected inspection, diagnosis and service tasks, including hydraulic clutch bleeding.

2B

Students use the Workshop Manual and required special tools to disassemble an MTX-75
transaxle and answer additional questions on the differential and other subassemblies.

3B

Students use the Workshop Manual and required special tools to assemble an MTX-75
transaxle and perform all end play measurements.

Manual Transmission/Transaxle Repair

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LESSON TWO

WORKSTATION 1B

WORKSTATION 1B
CLUTCH DIAGNOSIS AND SERVICE
DIRECTIONS: For this activity, you will use components and a mock-up of the hydraulic clutch system to
perform hydraulic clutch bleeding and selected clutch component inspections/tests. Refer to the 2006 Ranger
Workshop Manual, Section 308-00, and complete the following worksheet questions during the activities.
1. What tests are available for the clutch pressure plate?
_______________________________________________________________________________________
_______________________________________________________________________________________
2. What symptoms may be present if the pressure plate adjuster is misadjusted or damaged?
_______________________________________________________________________________________
_______________________________________________________________________________________
3. What tests are available for the clutch disc?
_______________________________________________________________________________________
_______________________________________________________________________________________


Refer to the 2006 Ranger Workshop Manual, Section 308-00, Pinpoint Test D. Start at Step D1 and work
through this Pinpoint Test to perform:

Visual Inspections

Hydraulic System Internal Check

Clutch Pedal Reserve

Clutch Pedal Free Play Check

Clutch Hydraulic System Bleeding

4. If you were performing a Clutch Pedal Reserve Check on an actual vehicle, what are some of the vehicle
preparation requirements that must be done first?
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
5. When the above requirements have been met, how is the Clutch Pedal Reserve check performed?
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
Continued on next page.

Manual Transmission/Transaxle Repair

2-2

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LESSON TWO

WORKSTATION 1B

6. What distance is being measured in the Clutch Pedal Free Play Check?
_______________________________________________________________________________________
_______________________________________________________________________________________
7. Besides opening the system for service, how else can air get into the clutch hydraulic system?
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
8. What conditions can be caused by air in the clutch hydraulic system?
_______________________________________________________________________________________
_______________________________________________________________________________________
9. What should an assistant do just before you loosen the bleeder screw to let air escape the clutch system?
_______________________________________________________________________________________
_______________________________________________________________________________________
INSTRUCTOR DEMO: Ask your instructor to demonstrate to you how to reset an adjustable pressure plate.
Refer to the 2006 Ranger Workshop Manual, Section 308-01, and answer the following questions:
10. During clutch disc and pressure plate installation, what alignment tool is required according to the Workshop
Manual?
_______________________________________________________________________________________
11. What is the maximum specification for tension spring adjustment when resetting the clutch pressure plate?
_______________________________________________________________________________________
12. What steps must be taken to reset the pressure plate?
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
13. If the original clutch pressure plate or flywheel are to be reused, what are you to do?
_______________________________________________________________________________________
14. What is the difference between the instructors demonstration of the adjustable pressure plate and the
adjustment procedure in the Workshop Manual?
_______________________________________________________________________________________
15. What were the press target areas on the pressure plate that are critical during the Instructor Demo on the
pressure plate?
_______________________________________________________________________________________
_______________________________________________________________________________________
Manual Transmission/Transaxle Repair

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LESSON TWO

WORKSTATION 2B

WORKSTATION 2B
MTX-75 TRANSAXLE DISASSEMBLY
DIRECTIONS: Complete Workstation 2B at the bench workstation, using the MTX-75 transaxle, available hand
tools and special service tools, and Workshop Manual.
SUMMARY: For this activity, you will disassemble an MTX-75 transaxle down to its major subassemblies,
performing any necessary inspections required by the 2006 Workshop Manual along the way.


Follow the Focus Service Information, Section 308-03, to disassemble the MTX-75 transaxle to its major
subassemblies. (Use the appropriate model year Workshop Manual for the transmission you have in class.)

As you perform the disassembly procedures, pay attention to the following questions related to key steps.

1. Is the release bearing assembly reusable? Why or why not?

_______________________________________________________________________________________
_______________________________________________________________________________________
2. To remove the shift tower assembly, in what position must the gearshift lever be placed?
_______________________________________________________________________________________
3. How are the input shaft and output shaft assemblies removed from the transaxle case?
_______________________________________________________________________________________
_______________________________________________________________________________________
4. What does the Workshop Manual recommend to assist in the removal of the differential, output shaft and
input shaft bearing races with the 308-001 slide hammer and adapter?
_______________________________________________________________________________________
5. When would you need to remove the reverse idler gear shaft from the case?
_______________________________________________________________________________________
6. Upon completion of the MTX-75 disassembly process, what subassemblies are left?
_______________________________________________________________________________________
Refer to the MTX-75 Subassembly procedures in the Workshop Manual to answer Questions 7-9.
NOTE: DO NOT disassemble the Input Shaft or the Output Shaft subassemblies.
7. When servicing the input shaft and output shaft assemblies, can needle bearings and synchronizer rings be
reused?
_______________________________________________________________________________________
8. If removed during disassembly, can input shaft, output shaft or differential bearings be reused? Why or why
not?
_______________________________________________________________________________________
_______________________________________________________________________________________
Continued on next page.

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LESSON TWO

WORKSTATION 2B

9. What can be replaced on the differential assembly, using the Workshop Manual?
_______________________________________________________________________________________
NOTE: The following questions refer ONLY to the disassembly, inspection and reassembly of the 5th/
Reverse synchronizer using the Output Shaft Subassembly section 308-03 of the 2006 Focus
Workshop Manual. Each student MUST disassemble and reassemble the synchronizer. Upon
completion, the instructor must sign-off in the space provided below.
10. How should the output shaft bearing be removed?
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
11. When removing the 5th/reverse gear synchronizer assembly, what parts are to be discarded?
_______________________________________________________________________________________
12. According to the Workshop Manual, why would a synchronizer need to be replaced?
_______________________________________________________________________________________
13. According to the Workshop Manual, what is a recommended aid for proper synchronizer assembly?
_______________________________________________________________________________________
_______________________________________________________________________________________

Instructor Sign-off: _______________________

Manual Transmission/Transaxle Repair

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August 2007

LESSON TWO

WORKSTATION 3B

WORKSTATION 3B
MTX-75 TRANSAXLE ASSEMBLY
DIRECTIONS: Complete Workstation 3B at the bench workstation, using the MTX-75 transaxle, available hand
tools and special service tools, and Workshop Manual.
SUMMARY: For this activity, you will assemble an MTX-75 transaxle, performing any necessary measurements
and inspections required by the Workshop Manual.


Follow the Focus Service Information, Section 308-03, to assemble the MTX-75 transaxle and perform any
necessary inspections and measurements. (Use the appropriate model year Workshop Manual for the
transmission you have in class.)

If adjustments are required, identify the correct size select-fit part that is needed.

1. When is it necessary for you to check input shaft endplay, output shaft and differential preloads?
_______________________________________________________________________________________
2. If new input shaft, output shaft and/or differential bearings are installed, what else must be done?
_______________________________________________________________________________________
3. List the nominal shim sizes required when initially installing the bearings on the clutch side.
Input shaft (Part No. F5RZ-7L172-DA):

__________ mm

(__________) inches

Output shaft (Part No. F5RZ-7N135-AA):

__________ mm

(__________) inches

Differential (Part No. 91ZZ-4067-XA):

__________ mm

(__________) inches

4. What is the purpose of Input Shaft Socket 308-224?

_______________________________________________________________________________________
5. Using the dial indicator and the Workshop Manual procedures, measure end play/preload per the table below
and calculate the shim required. Enter your answers in the appropriate spaces.
MTX-75 Required Shim Thickness
Type

Input Shaft (mm)

Output Shaft (mm)

Differential (mm)

Measuring shims

1.00

1.00

1.10

Determined end float

+ _________

+ _________

+ _________

+0.13

+0.33

Preload figure
End float

-0.05

Required shim thickness

= _________

= _________

= _________

Shims available

1.15-1.71 (in 0.01 mm steps)

1.31-1.91 (in 0.02 mm steps)

1.40-2.20 (in 0.05 mm steps)

6. How can you tell if the shift rail assemblies are installed correctly?
_______________________________________________________________________________________
7. After applying sealant to the case mating surface, attaching bolts must be installed and tightened within
__________ minutes. Sealer cures rapidly.

Manual Transmission/Transaxle Repair

2-6

August 2007