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Home >> Ford >> 2018 >> Focus SEL, 4D Hatchback >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 38 (Manual Transmission - 6-Speed Manual Transmission - B6) >> Removal And Installation >> 3rd-4th Gear Synchronizer >> Installation

3rd-4th Gear Synchronizer: Installation

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  1. Lubricate the parts in transmission fluid and install the 3rd gear bearing, 3rd gear and 3rd gear synchronizer assembly.

    Material

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

    GFD268756Courtesy of FORD MOTOR COMPANY
  2. Using the special tools, install the 3rd-4th gear synchronizer hub. Use Special Service Tool: 205-199 (T83T-3132-A1) Installer, Spindle/Axle Shaft.
    GFD268757Courtesy of FORD MOTOR COMPANY
    1. Install a new 3rd-4th gear synchronizer sleeve.
    2. Lubricate the 3rd-4th gear synchronizer sleeve detents in transmission fluid and install them so they fit in the 3rd-4th gear synchronizer hub as shown.

      Material

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

    GFD268758Courtesy of FORD MOTOR COMPANY
    1. Install the 3rd-4th gear synchronizer hub snap ring.
    2. Lubricate the parts in transmission fluid and install the 4th gear synchronizer assembly and install 4th gear.

      Material

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

    GFD268759Courtesy of FORD MOTOR COMPANY
    1. NOTE: Make sure that the components are installed to the position noted during removal.

      Install the 4th gear retainer.

    2. Lubricate the parts in transmission fluid and install 5th gear and the 5th gear synchronizer assembly.

      Material

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

    GFD268760Courtesy of FORD MOTOR COMPANY
  6. Using the special tools, install the 5th-6th gear synchronizer hub. Use Special Service Tool: 205-199 (T83T-3132-A1) Installer, Spindle/Axle Shaft. Use the General Equipment: Hydraulic Press
    GFD268761Courtesy of FORD MOTOR COMPANY
    1. Install the 5th-6th gear synchronizer sleeve.
    2. Lubricate the 5th-6th gear synchronizer sleeve detents in transmission fluid and install them so they fit in the 5th-6th gear synchronizer hub as shown.

      Material

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

    GFD268762Courtesy of FORD MOTOR COMPANY
    1. Install a new 5th-6th gear synchronizer hub snap ring.
    2. Lubricate the parts in transmission fluid and install the 6th gear synchronizer assembly and install 6th gear.

      Material

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

    GFD268763Courtesy of FORD MOTOR COMPANY
  9. Using the special tools, install a new rear bearing. Use Special Service Tool: 205-D015 (D80L-630-4) Step Plate. Use the General Equipment: Hydraulic Press
    GFD268764Courtesy of FORD MOTOR COMPANY
  10. Install a new rear bearing bolt.

    Torque

    : 81 lb.ft (110 Nm)

    GFD268765Courtesy of FORD MOTOR COMPANY
  11. NOTE: Install the lube tube in the same position as noted during disassembly.

    Install the lube tube and the magnet in the transmission case.

    Material

    : Motorcraft® Silicone Brake Caliper Grease and Dielectric Compound / XG-3-A (ESE-M1C171-A)

    GFD268766Courtesy of FORD MOTOR COMPANY
  12. Lubricate the output shaft roller bearing.

    Material

    : Motorcraft® Silicone Brake Caliper Grease and Dielectric Compound / XG-3-A (ESE-M1C171-A)

    GFD268767Courtesy of FORD MOTOR COMPANY
  13. Assemble the input shaft, output shaft and the shift forks.
    GFD268768Courtesy of FORD MOTOR COMPANY
    1. Lubricate the input shaft bearing and the shift rod bushing.

      Material

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

    2. NOTE: Be careful not to damage the bearings when installing the input shaft, output shaft and shift forks.

      Position the input shaft, output shaft and shift forks into the clutch housing.

    3. NOTE: Make sure the output shaft is aligned with the bearing so damage does not occur to the output shaft bearing.

      Align the output shaft with the output shaft roller bearing.

    4. Gently lower the input shaft, output shaft and shift forks and install them in the clutch housing.
    5. Lubricate the input shaft and output shaft rear bearings.

      Material

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

    GFD268769Courtesy of FORD MOTOR COMPANY
    1. Lubricate the reverse synchronizer sleeve detents in transmission fluid and install them so they fit in the reverse synchronizer hub as shown.
    2. Install the reverse synchronizer sleeve and reverse shift fork.

      Material

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

    GFD268770Courtesy of FORD MOTOR COMPANY
  16. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.

    Clean the sealing surfaces. Make sure that the mating faces are clean and free of foreign material.

    GFD268771Courtesy of FORD MOTOR COMPANY
    1. Install the special tools. Install Special Service Tool: 307-680 Table, Assembly (DPS6).
    2. Apply sealant to the clutch housing.

      Material

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

    GFD268772Courtesy of FORD MOTOR COMPANY
    1. NOTE: Make sure that new bolts are installed.

      Install the transmission case and install new bolts.

      Torque

      :Stage 1: 159 lb.in (18 Nm) Stage 2: 90°

    2. Remove Special Service Tool: 307-680 Table, Assembly (DPS6).
    GFD268773Courtesy of FORD MOTOR COMPANY
    1. NOTE: Make sure that new bolts are installed.

      Install new transmission case bolts.

      Torque

      :Stage 1: 159 lb.in (18 Nm) Stage 2: 90°

    2. NOTE: Make sure that new bolts are installed.

      Apply sealant to the underside of the bolts.

      Material

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

    3. Install new bolts.

      Torque

      : 177 lb.in (20 Nm)

    4. Position a new seal on the transmission case.
    5. Using the special tool, install the seal in the transmission case. Use Special Service Tool: 308-880 Installer, Driveshaft Seal.
    GFD268774Courtesy of FORD MOTOR COMPANY
  20. Make sure the transmission is in neutral.
    GFD268775Courtesy of FORD MOTOR COMPANY
  21. NOTE: Re-use the O-ring seal unless it is damaged.

    Lubricate and install the O-ring.

    Material

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

    GFD268776Courtesy of FORD MOTOR COMPANY
    1. Make sure that the shift forks are in the neutral (N) position.
    2. NOTE: Make sure that no components catch.

      Install the selector mechanism.

    3. Install the bolts.

      Torque

      : 18 lb.ft (24 Nm)

    GFD268777Courtesy of FORD MOTOR COMPANY
    1. NOTE: Use adhesive tape to cover the input shaft splines to prevent damage to the input shaft seal.

      Tape the input shaft. Use the General Equipment: Adhesive Tape

    2. NOTE: Make sure that a new component is installed.

      Position a new seal on the input shaft.

    3. Using the special tool, install the input shaft seal. Use Special Service Tool: 308-847 Installer, Input shaft Seal.
    4. Remove and discard the tape.
    GFD268778Courtesy of FORD MOTOR COMPANY
  24. Install the slave cylinder and the 2 bolts.

    Torque

    : 89 lb.in (10 Nm)

    GFD268520Courtesy of FORD MOTOR COMPANY
    1. Install new bolts.

      Torque

      :Stage 1: 159 lb.in (18 Nm) Stage 2: 90°

    2. Position a new LH halfshaft seal in the transmission.
    3. Using the special tool, install the LH halfshaft seal. Use Special Service Tool: 308-880 Installer, Driveshaft Seal.
    4. Remove Special Service Tool: 307-003 (T57L-500-B) Holding Fixture, Transmission.
GFD268779Courtesy of FORD MOTOR COMPANY
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