3rd-4th Gear Synchronizer: Installation

WARNING: This page is about a different car, the 2016 Ford Focus. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Use vise jaws protectors.

1.

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

Lubricate the synchronizer rings with manual transmission fluid before assembly.

Material: Motorcraft® Dual Clutch Transmission Fluid / XT-11-QDC (WSS-M2C200-D2)

2.

Assemble the following items:

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4.

NOTE: Make sure that a new component is installed.

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5.

Use Special Service Tool: 205-068 Installer, Drive Pinion Bearing. Use the General Equipment: Hydraulic Press

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6.

Install the following items:
1. NOTE: Make sure that a new component is installed.
2. Use Special Service Tool: 308-044 Installer, Transmission Extension Housing Bushing/Seal.

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7.

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

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8.

Keep the reverse gear idler shaft bearing block raised while installing the shaft. Use Special Service Tool: 308-214 Remover, Hydraulic Line Spring Clip.

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10.

Material: Motorcraft® Dual Clutch Transmission Fluid / XT-11-QDC (WSS-M2C200-D2)

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11.
- 1.
  
  Install the input and output shafts together.
- 2.
  
  Move the input and output shafts to one side.
- 3.
  
  Remove Special Service Tool: 308-214 Remover, Hydraulic Line Spring Clip.

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12.

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

Install the following items:

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13.

Install the following items:
1. Material: Motorcraft® Gasket Maker / TA-16 (WSK-M2G348-A5)
  Torque: 25 lb.ft (34 Nm)
2. 2.
3. 3.
4. 4.

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14.

Material: Motorcraft® Gasket Maker / TA-16 (WSK-M2G348-A5)

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15.

NOTE: The guide pins must remain installed in the gearbox housing.

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16.

Tighten the bolts in a crisscross sequence.
Torque: 30 lb.ft (40 Nm)

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17.

NOTE: Make sure that a new component is installed.

Use Special Service Tool: 205-115 Installer, Drive Pinion Seal.

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18.

NOTE: Make sure that a new component is installed.

Material: Motorcraft® Gasket Maker / TA-16 (WSK-M2G348-A5)

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19.

Install the following items:
1. NOTE: Make sure that a new component is installed.
  
  Use Special Service Tool: 205-115 Installer, Drive Pinion Seal.
2. NOTE: Use adhesive tape to cover the input shaft splines to prevent damage to the input shaft seal.
  
  NOTE: Make sure that a new component is installed.
3. NOTE: Make sure that new components are installed.
  
  Torque: 97 lb.in (11 Nm)

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20.

Remove the adhesive tape from the input shaft splines.

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22.

Material: Motorcraft® Gasket Maker / TA-16 (WSK-M2G348-A5)

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23.
- 2.
  
  NOTE: Note the different lengths of the bolts.
  
  Torque: 19 lb.ft (26 Nm)
- 3.
  
  Torque: 19 lb.ft (26 Nm)
- 4.
  
  Torque: 30 lb.ft (40 Nm)
- 5.
  
  Remove Special Service Tool: 205-329 Mounting Bracket, Engine/Differential., 303-435-06 Mounting Bracket for 303-435., 303-435 Mounting Stand.

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