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Section 1 (Automatic Dual Clutch Transaxle (DCT) POWERSHIFT (DPS6/6DCT250)): Assembly: Transmission

WARNING: This page is about a different variant/trim than selected.
SPECIAL TOOL(S) / GENERAL EQUIPMENT

G08064294
 204-594 
Forcing screw
G08064317
 205-118 
Differential bearing cap installer
TKIT-2009TC-F
G08064334
 205-125 
Gauge, Disc
G08064159
 307-580 
Holding Fixture
TKIT-2006UF-FLM
G08064068
 307-671 
Installer, Axle Seal
G08064102
 307-672 
Installer, Input Guide and Seal
G08064259
 307-680 
Table, Assembly (DPS6)
G08064339
 307-681 
Differential Bearing Preload Tool
G08064340
 308-164 
Shim Selection Set
Feeler Gauge
Hot Air Gun
Punch
MATERIALS SPECIFICATIONS

Name Specification
Gasket Maker
TA-16		 WSK-M2G348-A5
  1. NOTE: Take extra care not to damage the seal.
    Fig 1: Installing Input Shaft
    G07979799Courtesy of FORD MOTOR CO.
    2. NOTE: Apply pressure on the synchronizer ring whilst taking the measurements.
    NOTE: If the clearance is less than the minimum measurement stated in the Specifications , install a new shaft assembly.
    Fig 2: Measuring Clearance Between Synchronizer Ring And Gear Using Feeler Gauge
    G07979800Courtesy of FORD MOTOR CO.
  2. Using a suitable feeler gauge, measure the clearance between the synchronizer ring and gear in various places around the circumference.
    3. NOTE: Apply pressure on the synchronizer ring whilst taking the measurements.
    NOTE: If the clearance is less than the minimum measurement stated in the Specifications , install a new shaft assembly.
    Fig 3: Measuring Clearance Between Synchronizer Ring And Gear Using Feeler Gauge
    G07979801Courtesy of FORD MOTOR CO.
  3. Using a suitable feeler gauge, measure the clearance between the synchronizer ring and gear in various places around the circumference.
    4. NOTE: Make sure that the syncros are in the neutral position.
    Fig 4: Installing Syncros In Neutral Position Using Special Tools
    G08064292Courtesy of FORD MOTOR CO.
  4. Special Tool(s)  : 307-680 (Table, Assembly (DPS6)) 
  5. Special Tool(s)  : 307-680 (Table, Assembly (DPS6)) 
    Fig 5: Installing Synchronizer Ring And Gear Using Special Tools
    G08064345Courtesy of FORD MOTOR CO.
  6. Special Tool(s)  : 307-680 (Table, Assembly (DPS6)) 
    Fig 6: Installing Synchronizer Ring And Gear Using Special Tools
    G08064346Courtesy of FORD MOTOR CO.
    7. NOTE: After installing the assembly table place the gear assembly in the upright position.
    Fig 7: Installing Assembly Table Gear Assembly In Upright Position Using Special Tools
    G08064289Courtesy of FORD MOTOR CO.
  7. Special Tool(s)  : 307-680 (Table, Assembly (DPS6)) 
  8. Remove the Special Tool(s)  : 307-680 (Table, Assembly (DPS6)) 
    Fig 8: Identifying Special Tools 307-680 (Table, Assembly - DPS6)
    G08064348Courtesy of FORD MOTOR CO.
  9. Fig 9: Locating Shift Drum
    G07979808Courtesy of FORD MOTOR CO.
  10. NOTE: Make sure the shift drums are in the neutral position.
    Fig 10: Locating Shift Drums In Neutral Position
    G07979809Courtesy of FORD MOTOR CO.
  11. NOTE: Make sure the shift drums are in the neutral position.
    Fig 11: Installing Shift Drums In Neutral Position
    G07979810Courtesy of FORD MOTOR CO.
  12. Fig 12: Locating 3rd Gear Linkage And Shift Drum 2
    G07979811Courtesy of FORD MOTOR CO.
  13. Fig 13: Locating 1st/5th Gear Shift Fork
    G07979812Courtesy of FORD MOTOR CO.
  14. Fig 14: Locating 3rd Gear Shift Fork
    G07979813Courtesy of FORD MOTOR CO.
  15. Fig 15: Identifying Shift Fork Rods
    G07979814Courtesy of FORD MOTOR CO.
  16. Fig 16: Locating Oil Spout
    G07979788Courtesy of FORD MOTOR CO.
    17. NOTE: Make sure that the bearing retainers are correctly located.
    Fig 17: Identifying Special Tools 307-680 (Table, Assembly - DPS6)
    G08064357Courtesy of FORD MOTOR CO.
  17. Special Tool(s)  : 307-680 (Table, Assembly (DPS6)) 
  18. Fig 18: Installing Differential Housing
    G07979817Courtesy of FORD MOTOR CO.
  19. Torque  : 32 Nm
    Fig 19: Locating Differential Housing Bolts
    G07979784Courtesy of FORD MOTOR CO.
  20. Special Tool(s)  : 307-580 (Holding Fixture) 
    Fig 20: Identifying Special Tools 307-580 (Holding Fixture)
    G07979783Courtesy of FORD MOTOR CO.
  21. Remove the Special Tool(s)  : 307-680 (Table, Assembly (DPS6)) 
    Fig 21: Identifying Special Tools 307-680 (Table, Assembly - DPS6)
    G07979781Courtesy of FORD MOTOR CO.
  22. Fig 22: Locating Differential Housing Mark
    G07979780Courtesy of FORD MOTOR CO.
  23. Fig 23: Installing Differential Housing Side Gear
    G07979822Courtesy of FORD MOTOR CO.
  24. Fig 24: Installing Differential Housing Side Gear Pawl Pins
    G07979823Courtesy of FORD MOTOR CO.
  25. Fig 25: Removing Pawl Pin To Actuation Shaft Guide
    G07979777Courtesy of FORD MOTOR CO.
  26. NOTE: Make sure that the pawl pin is aligned to the actuation shaft guide.
    Fig 26: Locating Actuation Shaft Guide And Pawl Pin
    G07979776Courtesy of FORD MOTOR CO.
  27. Fig 27: Locating Differential Housing
    G07979440Courtesy of FORD MOTOR CO.
  28. NOTE: The following 8 steps are only required when replacing the differential housing bearings.
    Fig 28: Locating Differential Housing Bearing
    G07979442Courtesy of FORD MOTOR CO.
  29. Special Tool(s)  : 307-681 (Differential Bearing Preload Tool)  , 308-164 (Shim Selection Set) 
    Fig 29: Identifying Special Tools 307-681 (Differential Bearing Preload Tool) 308-164 (Shim Selection Set)
    G08064369Courtesy of FORD MOTOR CO.
  30. Special Tool(s)  : 307-681 (Differential Bearing Preload Tool) 

    Torque  : 18 Nm

    Fig 30: Identifying Special Tools 307-681 (Differential Bearing Preload Tool)
    G08064370Courtesy of FORD MOTOR CO.
  31. Special Tool(s)  : 307-681 (Differential Bearing Preload Tool) 
    Fig 31: Moving Differential Bearing Using Special Tools
    G08064371Courtesy of FORD MOTOR CO.
  32. Special Tool(s)  : 307-681 (Differential Bearing Preload Tool) 
    Fig 32: Turning Differential Bearing Bolt Using Special Tools
    G07979446Courtesy of FORD MOTOR CO.
  33. Using a suitable feeler gauge, measure the clearance at the 3 locations shown in illustration.

    General Equipment  : Feeler Gauge

    Fig 33: Measuring Differential Bearing Clearance Using Feeler Gauge
    G07979447Courtesy of FORD MOTOR CO.
  34. Remove the special tools.
    35. NOTE: The shim size should be the average of the 3 measurements.
    NOTE: Using the average of the recorded measurements, select the appropriate shim from the shim selection chart in the Specifications .
    Fig 34: Locating Clutch Housing Shim
    G08064374Courtesy of FORD MOTOR CO.
  35. Install the selected shim into the clutch housing.
  36. Special Tool(s)  : 204-594 (Forcing screw)  , 205-118 (Differential bearing cap installer)  , 307-671 (Installer, Axle Seal) 
    Fig 35: Installing Differential Bearing Cap Using Special Tools
    G08064375Courtesy of FORD MOTOR CO.
    37. NOTE: Make sure that a new component is installed.
    Fig 36: Identifying Special Tools 204-594 (Forcing Screw) 205-118 (Differential Bearing Cap Installer) 205-125 (Gauge, Disc)
    G08064376Courtesy of FORD MOTOR CO.
  37. Special Tool(s)  : 204-594 (Forcing screw)  , 205-118 (Differential bearing cap installer)  , 205-125 (Gauge, Disc) 
  38. Fig 37: Locating Transmission Clutch Housing Bolts
    G08064271Courtesy of FORD MOTOR CO.
    39. NOTE: Take extra care not to overheat the bearing.
    Fig 38: Heating Transmission Clutch Housing Bearing Using Hot Air Gun
    G07979830Courtesy of FORD MOTOR CO.
  39. General Equipment  : Hot Air Gun
  40. Material  : Gasket Maker / TA-16 (WSK-M2G348-A5)
    Fig 39: Marking Transmission Clutch Housing Gasket
    G07979827Courtesy of FORD MOTOR CO.
  41. Fig 40: Installing Transmission Clutch Housing
    G07979831Courtesy of FORD MOTOR CO.
  42. Torque  : 27 Nm
    Fig 41: Locating Transmission Clutch Housing Cover Bolts
    G07979769Courtesy of FORD MOTOR CO.
  43. Torque  : 27 Nm
    Fig 42: Locating Transmission Clutch Housing Bolts
    G07979768Courtesy of FORD MOTOR CO.
  44. General Equipment  : Punch

    Torque  : 43 Nm

    Fig 43: Punching Transmission Clutch Housing
    G08064383Courtesy of FORD MOTOR CO.
    45. NOTE: Make sure that a new component is installed.
    Fig 44: Locating Manual Control Lever Bolt
    G07979837Courtesy of FORD MOTOR CO.
  45. Torque  : 26 Nm
  46. NOTE: Make sure that a new component is installed.
    Fig 45: Locating Input Shaft Seal Ring
    G07979838Courtesy of FORD MOTOR CO.
    47. NOTE: Use a new seal.
    Fig 46: Installing Input Guide And Seal Using Special Tools
    G08064386Courtesy of FORD MOTOR CO.
  47. Special Tool(s)  : 307-672 (Installer, Input Guide and Seal) 
    48. NOTE: Make sure that the bolt heads are not protruding above the housing surface.
    Fig 47: Locating Input Shaft Seal Housing Surface Mounting Bolts
    G08064107Courtesy of FORD MOTOR CO.
  48. Torque  : 8 Nm
  49. Install the following items:
    1. Refer to: Transmission Range (TR) Sensor  .
    2. Refer to: Output Shaft Speed (OSS) Sensor  .
    3. Refer to: Input Shaft Speed (ISS) Sensor  .
    4. Refer to: Transmission Control Module (TCM)  .
    5. Refer to: Clutch Actuator  .
    6. Refer to: Clutch Actuator Motor  .
    7. Refer to: Clutch Unit  .
  50. Refer to: Transmission - 2.0L Duratec-HE  .
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