Manual Transaxle - Overview
Location of components
Overview of external components
| Item | Description |
|---|---|
| 1 | Vent assembly |
| 2 | Internal gearshift mechanism |
| 3 | Reverse gear switch |
| Item | Description |
|---|---|
| 1 | Vent assembly |
| 2 | Internal gearshift mechanism |
| 3 | Reverse gear and Neutral Position switch |
Overview of inner components
| Item | Description |
|---|---|
| 1 | Crown wheel with differential |
| 2 | Reverse gear idler wheel |
| 3 | Selector fork - reverse gear |
| 4 | 5th gear idler wheel |
| 5 | 5th/6th gear selector fork |
| 6 | 6th gear idler wheel |
| 7 | 5th/6th/Reverse Gear Output Shaft |
| 8 | Selector rod - 5th/6th/reverse gear |
| 9 | Input shaft |
| 10 | 1st - 4th gear output shaft |
| 11 | 4th/6th gear fixed wheel |
| 12 | Selector rod - 1st/4th gear |
| 13 | Selector fork - 3rd/4th gear |
| 14 | 3rd gear fixed wheel |
| 15 | 5th gear fixed wheel |
| 16 | Selector fork - 1st/2nd gear |
| 17 | 1st gear fixed wheel |
All gear wheels are helical toothed and are constantly engaged
1st and 2nd gear have triple synchronizers.
3rd and 4th gear have double synchronizers.
5th and 6th gear and reverse gear have single synchronizers.
By optimizing the friction in the transmission and using a lower viscosity transmission fluid, it has been possible to achieve fuel savings and thereby reduce CO2 emissions. Information on the specification can be found in FordEtis.
In addition, the gearshift cables have also been adapted.
Input shaft
| Item | Description |
|---|---|
| 1 | Input shaft |
| 2 | Input shaft bearing |
| 3 | 1st gear |
| 4 | 2nd gear |
| 5 | 5th gear |
| 6 | 3rd gear |
| 7 | 4th/6th gear |
| 8 | Input shaft ball bearing |
| 9 | Bearing retaining bolt |
All driving gear wheels of the transmission are located on the input shaft.
The input shaft is designed as a solid shaft and runs on one ball bearing and one roller bearing with no pre-load.
The gear wheels for 1st and 2nd gear are an integral part of the input shaft. The gearwheels for 3rd and 5th gears and the gearwheel for 4th/6th gear are pressed on.
Because of the high force used to press on the components, the gear wheels cannot be pressed off in service. A faulty input shaft can only be replaced as a complete unit.
Defective bearings can be pressed off and changed.
Output shaft 1st/4th gear
| Item | Description |
|---|---|
| 1 | Clutch housing taper roller bearing |
| 2 | 1st/4th gear output shaft toothing |
| 3 | 1st gear wheel and reverse gear idler gear |
| 4 | 1st/2nd gear sleeve |
| 5 | 1st/2nd gear synchronizer hub |
| 6 | Gear wheel (2nd gear) |
| 7 | Gear wheel (3rd gear) |
| 8 | 3rd/4th gear synchronizer hub |
| 9 | 3rd/4th gear sliding collar |
| 10 | Snap ring |
| 11 | 1st/2nd gear synchronizer |
| 12 | Stop disc unit |
| 13 | 3rd/4th gear synchronizer |
| 14 | Gear wheel (4th gear) |
| 15 | Transmission housing taper roller bearing |
| 16 | Bearing retaining bolt (left-hand thread) |
The output pinion of the 1st/4th gear output shaft is an integral part of the shaft.
The synchronizers of the 1st/2nd and the 3rd/4th gears are located on the output shaft.
The 1st/4th gear output shaft is a hollow shaft. The fluid is directed into the inner diameter of the hollow shaft for lubrication of the needle bearings and the synchronizer units. Both output shafts run on taper roller bearings which are pre-loaded with the aid of adjusting shims in the clutch housing.
5th/6th/Reverse Gear Output Shaft
| Item | Description |
|---|---|
| 1 | Clutch housing taper roller bearing |
| 2 | 5th/6th/reverse gear output shaft toothing |
| 3 | Reverse gear gearwheel |
| 4 | Reverse gear sliding sleeve |
| 5 | Reverse gear synchronizer hub |
| 6 | Snap ring |
| 7 | 5th/6th gear synchronizer hub |
| 8 | Reverse gear synchronizer |
| 9 | Stop disc unit |
| 10 | Gear wheel (5th gear) |
| 11 | 5th/6th gear sliding collar |
| 12 | 5th/6th gear synchronizer |
| 13 | 6th gear wheel |
| 14 | Taper roller bearing, transmission housing |
| 15 | Bearing retaining bolt (left-hand thread) |
The output pinion is an integral part of the shaft.
The 5th/6th and reverse gear synchronizer assemblies are located on the shaft.
The 5th/6th/reverse gear output shaft is a hollow shaft. The fluid is directed into the inner diameter of the hollow shaft for lubrication of the needle bearings and the synchronizer units. Both output shafts run on taper roller bearings which are pre-loaded with the aid of adjusting shims in the clutch housing.
Differential
| Item | Description |
|---|---|
| 1 | Shim |
| 2 | Clutch housing taper roller bearing |
| 3 | Differential |
| 4 | Ring gear bolts |
| 5 | Transmission housing taper roller bearing |
| 6 | Ring gear |
The differential runs on taper roller bearings and is pre-loaded with the aid of an adjusting shim in the clutch housing.