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Section 122 (Manual Transaxle/Transmission - Mt82 GETRAG 6-Speed): Disassembly: Transmission

WARNING: This page is about a different car, the 2013 Ford Mustang. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOLS

G06125059
 2 Jaw Puller
205-D026 (D80L-1002-L) or equivalent
G06061933
 2 or 3 Jaw Puller
205-D027 (D80L-1013-A) or equivalent
G06065006
 Handle
205-153 (T80T-4000-W)
G06125113
 Holding Fixture, Transmission
307-003 (T57L-500-B)
G07488802
 Holding Tool, Drive Pinion Flange
205-478
G07488803
 Holding Tool, Rear Flange
308-807
G07488684
 Installer, Shift Rail Needle Bearing
308-130 (T87T-7025-DH)
G07488685
 Remover, Detent
308-812
G06068337
 Push/Puller Set
205-DS023 (D80L-927-A) or equivalent
G06404563
 Remover, Input Shaft Oil Seal
308-375
G07488688
 Remover, Synchro Gear Pack
308-810
G06064997
 Slide Hammer
100-001 (T50T-100-A)
G06068433
 Step Plate
205-D013 (D80L-630-2) or equivalent
MATERIAL SPECIFICATIONS

Item Specification
Motorcraft® Dual Clutch Transmission Fluid
XT-11-QDC		 WSS-M2C200-D2
WARNING: Do not breathe dust or use compressed air to blow dust from storage containers or friction components. Remove dust using government-approved techniques. Friction component dust may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure to follow these instructions may result in serious personal injury.
NOTE: For additional information on component views and base part numbers, refer to Transmission .
  1. Clean the transmission exterior with solvent and dry with compressed air. During disassembly, clean all components with solvent and dry with compressed air.
  2. Attach the transmission to the Transmission Holding Fixture.
    G07488691
  3. Remove the clutch slave cylinder and if equipped, the clutch slave cylinder spacer.
    1. Remove the 2 clutch slave cylinder bolts.
    2. Pull the clutch slave cylinder outward and release the tube from the retaining clip.
      G07488692
  4. Inspect the clutch slave cylinder for the following:
    • Damaged boot
    • Leaking brake fluid
    • Worn or damaged release bearing
      • Rotate the release bearing while applying pressure. If the bearing rotation is rough, install a new clutch slave cylinder.
  5. Using the Input Shaft Oil Seal Remover and the Slide Hammer, remove and discard the input shaft seal.
    G07488677
  6. Using a center punch, mark a location in the center of the countershaft bolt cover. Using a drill bit of the appropriate size for a suitable dent puller, drill a hole in the center of the countershaft bolt cover. Drill the hole to pierce the countershaft bolt cover approximately 2 mm (0.078 in) in depth.
    G07488694
  7. Using the Slide Hammer and a suitable dent puller, remove the countershaft bolt cover.
    G07488693
  8. Install the Rear Flange Holding Tool and the Drive Pinion Flange Holding Tool. Position the shift shaft into 4th gear.
    G07488696
  9. With the help of an assistant, hold the Rear Flange Holding Tool and the Drive Pinion Flange Holding Tool and remove the countershaft bolt.
    G07488697
  10. Using the Rear Flange Holding Tool and the Drive Pinion Flange Holding Tool, hold the output shaft flange and remove the output shaft flange bolt.
    G07488698
  11. Using the 2 or 3 Jaw Puller and the Step Plate, remove the output shaft flange.
    G07488699
  12. Using a suitable tool, remove the output shaft seal.
    G07488700
  13. Remove the Output Shaft Speed (OSS) sensor bolt and the OSS sensor.
    G07488701
  14. Remove the reverse lamp switch.
    1. Detach the electrical connector retainer.
    2. Remove the reverse lamp switch.
      G07488702
  15. If equipped, remove the 2 skip shift solenoid bolts and the skip shift solenoid.
    G07488703
  16. If equipped, use a magnet to remove the skip shift solenoid pin and spring.
    G07488704
  17. Remove the LH and RH reverse gear shift fork pivot bolts.
    G07488705
  18. Using the Detent Remover and the Slide Hammer, remove the 4 shift rail detents.
    G07488706
  19. Remove the 15 transmission case bolts.
    G07488707
  20. Using the 2 Jaw Puller and the Step Plate, apply a small amount of penetrating oil to the dowel pin locations. Tap the case with a bronze hammer while pulling it off to aid in removal of rear case.
    G07488708
  21. NOTE: To remove the reverse shift fork and the reverse shift rail assembly, the transmission must be in neutral and the groves on the shift rails must be aligned with the interlock plate.

    Remove the reverse shift fork and the reverse shift rail assembly.

    • Inspect the reverse shift fork and the reverse shift rail assembly for wear or damage. Install new components as necessary.
      G07488709
  22. Using the Detent Remover and the Slide Hammer, remove the shift shaft stop pin.
    G07488710
  23. Remove the shift shaft.
    G07488711
  24. Using the Push/Puller Set, Step Plate and the Synchro Gear Pack Remover, remove the 1st gear, the reverse gear and the reverse gear synchronizer assembly.
    • Inspect the 1st and reverse gears for wear or damage. Install new gears as necessary.
    • Inspect the reverse gear needle bearing and the reverse gear needle bearing race for wear or damage. Install new components as necessary.
    • Inspect the reverse gear synchronizer assembly and the reverse gear synchronizer ring for wear or damage. Install new components as necessary.
      G07488712
  25. Remove the 1st gear needle bearing.
    • Inspect the 1st gear needle bearing for wear or damage. Install a new 1st gear needle bearing as necessary.
      G07488713
  26. NOTE: Note the position of each synchronizer ring component before removal.

    Remove the 1st gear synchronizer ring assembly.

    • Inspect all synchronizer ring components for wear or damage. Install new components as necessary.
      G07488714
  27. NOTE: Slide the synchronizer sleeve up while removing the pressure pieces.

    Remove the 3 pressure pieces.

    G07488715
  28. NOTE: Index-mark the synchronizer sleeve to the synchronizer hub before removal.

    Remove the 1st/2nd shift fork, the 1st/2nd shift rail and the 1st/2nd synchronizer sleeve.

    • Inspect the 1st/2nd shift fork and the 1st/2nd shift rail for wear or damage. Install new components as necessary.
    • Inspect the 1st/2nd synchronizer sleeve for wear or damage. Install a new 1st/2nd synchronizer assembly as necessary.
      G07488716
  29. Remove the magnet.
    G07488717
  30. Remove the 2 bolts, spacers, spring and the interlock plate.
    G07488718
  31. Remove the 3 center support bolts.
    G07488719
  32. Remove the 1st/2nd synchronizer hub snap ring.
    G07488720
  33. NOTE: The center support must be pulled up evenly or damage to the center support or transmission case can occur.

    Using the Push/Puller Set, Step Plate and the Synchro Gear Pack Remover under the center support pull off the center support, 2nd gear and the 1st/2nd synchronizer hub.

    G07488721
  34. NOTE: Note the position of each synchronizer ring component before removal.

    Remove the 1st/2nd synchronizer hub, the 2nd gear synchronizer ring assembly and the 2nd gear.

    • Inspect all the components for wear or damage. Install new components as necessary.
      G07488722
  35. Remove the 2nd gear needle bearing.
    • Inspect the 2nd gear needle bearing for wear or damage. Install a new needle bearing as necessary.
      G07488723
  36. Remove the center support.
    • Inspect the center support for wear or damage. Install a new center support as necessary.
      G07488724
  37. NOTE: When removing the bearings, do not over expand the bearing cages or damage to the bearing cages can occur.

    Unlock the bearing cage tabs and slightly expand the bearing cages. Remove the center support bearings by sliding them up the shaft assemblies.

    G07488725
  38. Remove the 2 LH and the 2 RH shift fork pivot bolts.
    G07488819
  39. Remove the 3rd/4th shift rail and the 3rd/4th shift fork.
    G07488727
  40. Remove the 5th/6th shift rail and the 5th/6th shift fork.
    G07990796
  41. WARNING: Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury.
    NOTE: Use an assistant when pressing out the countershaft and output shaft, do not allow the shafts to bind during removal.
    NOTE: The countershaft bolt must be removed prior to pressing out the countershaft or damage to the transmission case will occur.

    With an assistant, support the transmission case on flat surfaces of a hydraulic press. Using the Shift Rail Needle Bearing Installer and the Handle, press the countershaft out of the bearing and remove the countershaft and output shaft.

    G07488729
  42. Remove the input shaft snap ring.
    G07488730
  43. WARNING: Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury.
    NOTE: Use an assistant when pressing out the input shaft, do not allow the input shaft to drop during removal.

    With an assistant, support the transmission case on flat surfaces of a hydraulic press. Using the hydraulic press, remove the input shaft.

    G07488731
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