3rd-4th Gear Synchronizer: Installation

WARNING: This page is about a different variant/trim than selected.

NOTE: Use vise jaws protectors.

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)
Assemble the following items:

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NOTE: Make sure that a new component is installed.

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

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

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

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

Install the following items:

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

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

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Tighten the bolts in a crisscross sequence.
Torque

: 30 lb.ft (40 Nm)

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NOTE: Make sure that a new component is installed.

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

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NOTE: Make sure that a new component is installed.

Material

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

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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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Remove the adhesive tape from the input shaft splines.

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

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NOTE: Note the different lengths of the bolts.

Torque

: 19 lb.ft (26 Nm)
Torque
: 19 lb.ft (26 Nm)
Torque
: 30 lb.ft (40 Nm)
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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