Ford Fiesta: Manual Transmission - 6-Speed Manual Transmission – B6 / Output 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
Hydraulic Press
Hot Air Gun
Bearing Separator
Vise
Vise Jaw Protectors

Materials

DISASSEMBLY

NOTE: If the front bearing needs to be replaced, replace the output shaft.

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

   Install the output shaft in a vise. Clamp the output shaft on the flat surfaces.
   Use the General Equipment: Vise
   Use the General Equipment: Vise Jaw Protectors

1. NOTE: The component has a left-hand thread.

   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 the output shaft rear bearing.
   Use Special Service Tool: 211-014  Remover, Steering Wheel.

1. NOTE: Only tighten the bolts on the bearing separator finger tight.

   Remove 6th gear.
   Use Special Service Tool: 205-D015 (D80L-630-4)  Step Plate.
   Use the General Equipment: Hydraulic Press
   Use the General Equipment: Bearing Separator

1. NOTE: Only tighten the bolts on the bearing separator finger tight.

   Remove 5th and 4th gear.
   Use the General Equipment: Bearing Separator
   Use the General Equipment: Hydraulic Press

1. 1. Push the 1st-2nd gear synchronizer sleeve down to the 1st gear position.
      
   2. Remove 2nd and 3rd gear.
      Use the General Equipment: Bearing Separator
      Use the General Equipment: Hydraulic Press

1. Remove the 2nd gear synchronizer assembly.
   

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

   1. Remove the 1st-2nd gear synchronizer sleeve.
      
   2. Remove the detents.
      

1. Remove the 1st-2nd gear synchronizer hub.
   Use the General Equipment: Hydraulic Press

1. Remove 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 1st gear.
   Material: Motorcraft® Dual Clutch Transmission Fluid / XT-11-QDC (WSS-M2C200-D2)

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

1. Using the special tools, install the 1st-2nd gear synchronizer hub. Align the hub with the 1st gear synchronizer.
   Use Special Service Tool: 205-D015 (D80L-630-4)  Step Plate.
   Use the General Equipment: Hydraulic Press

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

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

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

1. Using the special tools, install 3rd gear.
   Use Special Service Tool: 205-199 (T83T-3132-A1)  Installer, Spindle/Axle Shaft.
   Use the General Equipment: Hydraulic Press

1. Using the special tools, install 4th gear.
   Use Special Service Tool: 205-199 (T83T-3132-A1)  Installer, Spindle/Axle Shaft.
   Use the General Equipment: Hydraulic Press

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

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

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

1. NOTICE: Use vise jaw protectors.

   Install the output shaft in a vise. Clamp the output shaft on the flat surfaces.
   Use the General Equipment: Vise
   Use the General Equipment: Vise Jaw Protectors

1. NOTE: The component has a left-hand thread.

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