Ford Fiesta: Manual Transmission - 6-Speed Manual Transmission – B6 / Input Shaft. Disassembly and Assembly of Subassemblies

Special Tool(s) / General Equipment

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

Materials

DISASSEMBLY

1. • 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

1. NOTICE: Use vise jaw protectors or damage to the splines can occur.

   1. Install the input shaft in a vice.
      Use the General Equipment: Vise
   2. Use vice jaw protectors.
      Use the General Equipment: Vise Jaw Protectors

1. Heat the bolt to melt the Loctite® and remove and discard the rear bearing bolt.
   Use the General Equipment: Hot Air Gun

1. Using the special tools, remove and discard the rear bearing.
   Use Special Service Tool: 211-014  Remover, Steering Wheel.

1. Remove 6th gear, 6th gear synchronizer assembly and remove and discard the 5th-6th gear synchronizer hub snap ring.
   

1. Remove the 5th-6th gear synchronizer sleeve and the 3 detents.
   

1. Using the special tools, remove the 5th-6th gear synchronizer hub, 5th gear synchronizer assembly and 5th gear.
   Use the General Equipment: Bearing Separator
   Use the General Equipment: Hydraulic Press

1. NOTE: Note the position of the components before removal.

   Remove the 4th gear retainer, 4th gear and the 4th gear synchronizer assembly. Remove and discard the 3rd-4th gear synchronizer hub snap ring.
   

1. Remove the 3rd-4th gear synchronizer sleeve and the detents.
   

1. Using the special tools, remove the 3rd-4th gear synchronizer hub, 3rd gear synchronizer assembly, and 3rd gear.
   Use the General Equipment: Bearing Separator
   Use the General Equipment: Hydraulic Press

1. Remove the 3rd gear bearing.
   

ASSEMBLY

1. NOTICE: Use vise jaw protectors or damage to the splines can occur.

   1. Install the input shaft in a vice.
      Use the General Equipment: Vise
   2. Use vice jaw protectors.
      Use the General Equipment: Vise Jaw Protectors

1. Lubricate the parts in transmission fluid and install the 3rd gear bearing, 3rd gear and 3rd gear synchronizer assembly.
   Material: Motorcraft® Dual Clutch Transmission Fluid / XT-11-QDC (WSS-M2C200-D2)

1. Using the special tools, install the 3rd-4th gear synchronizer hub.
   Use Special Service Tool: 205-199 (T83T-3132-A1)  Installer, Spindle/Axle Shaft.

1. 1. Install the 3rd-4th gear synchronizer sleeve.
      
   2. Lubricate the 3rd-4th gear synchronizer sleeve detents in transmission fluid and install them so they fit in the 3rd-4th gear synchronizer hub as shown.
      Material: Motorcraft® Dual Clutch Transmission Fluid / XT-11-QDC (WSS-M2C200-D2)

1. 1. Install the 3rd-4th gear synchronizer hub snap ring.
      
   2. Lubricate the parts in transmission fluid and install the 4th gear synchronizer assembly and install 4th gear.
      Material: Motorcraft® Dual Clutch Transmission Fluid / XT-11-QDC (WSS-M2C200-D2)

1. 1. NOTE: Make sure that the components are installed to the position noted during removal.

      Install the 4th gear retainer.
      
   2. Lubricate the parts in transmission fluid and install 5th gear and the 5th gear synchronizer assembly.
      Material: Motorcraft® Dual Clutch Transmission Fluid / XT-11-QDC (WSS-M2C200-D2)

1. Using the special tools, install the 5th-6th gear synchronizer hub.
   Use Special Service Tool: 205-199 (T83T-3132-A1)  Installer, Spindle/Axle Shaft.
   Use the General Equipment: Hydraulic Press

1. 1. Install the 5th-6th gear synchronizer sleeve.
      
   2. Lubricate the 5th-6th gear synchronizer sleeve detents in transmission fluid and install them so they fit in the 5th-6th gear synchronizer hub as shown.
      Material: Motorcraft® Dual Clutch Transmission Fluid / XT-11-QDC (WSS-M2C200-D2)

1. 1. Install a new 5th-6th gear synchronizer hub snap ring.
      
   2. Lubricate the parts in transmission fluid and install the 6th gear synchronizer assembly and install 6th gear.
      Material: Motorcraft® Dual Clutch Transmission Fluid / XT-11-QDC (WSS-M2C200-D2)

1. Using the special tools, install the rear bearing.
   Use Special Service Tool: 205-D015 (D80L-630-4)  Step Plate.
   Use the General Equipment: Hydraulic Press

1. Install a new rear bearing bolt.
   Torque: 81 lb.ft (110 Nm)

1. 1. Position the front bearing on the input shaft.
      
   2. Using the special tools, install the front bearing.
      Use Special Service Tool: 307-679  Installer, Countershaft Needle Bearing.
      Use the General Equipment: Hydraulic Press
   3. Install a new snap ring.