manual transmission/ transaxle repair - dealerconnection · manual transmission/transaxle repair...

28
Ford Customer Service Division Technical Training Student Guide FCS-14836-REF Course Code: 36S12T0 August 2007 36 - Manual Transmission & Drivetrain Manual Transmission/ Transaxle Repair

Upload: others

Post on 17-Oct-2019

167 views

Category:

Documents


8 download

TRANSCRIPT

Page 1: Manual Transmission/ Transaxle Repair - DealerConnection · MANUAL TRANSMISSION/TRANSAXLE REPAIR INTRODUCTION Manual Transmission/Transaxle Repair Intro - 3 August 2007 Course Requirements

Ford Customer Service DivisionTechnical Training

Student Guide

FCS-14836-REF

Course Code: 36S12T0

August 2007

36 - Manual Transmission & Drivetrain

Manual Transmission/Transaxle Repair

Page 2: Manual Transmission/ Transaxle Repair - DealerConnection · MANUAL TRANSMISSION/TRANSAXLE REPAIR INTRODUCTION Manual Transmission/Transaxle Repair Intro - 3 August 2007 Course Requirements

Blank

Page 3: Manual Transmission/ Transaxle Repair - DealerConnection · MANUAL TRANSMISSION/TRANSAXLE REPAIR INTRODUCTION Manual Transmission/Transaxle Repair Intro - 3 August 2007 Course Requirements

IMPORTANT SAFETY NOTICE

Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles,as well as the personal safety of the individual doing the work. This manual provides general directions for accomplishingservice and repair work with tested, effective techniques. Following them will help assure reliability.

There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of theindividual doing the work. This manual cannot possibly anticipate all such variations and provide advice or cautions as to each.Accordingly, anyone who departs from instructions provided in this manual must first establish that he compromises neitherhis personal safety nor the vehicle integrity by his choice of methods, tools or parts.

As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each one is there for aspecific purpose. NOTES give you added information that will help you to complete a particular procedure. CAUTIONS aregiven to prevent you from making an error that could damage the vehicle. WARNINGS remind you to be especially carefulin those areas where carelessness can cause personal injury. The following list contains some general WARNINGS that youshould follow when you work on a vehicle.

Always wear safety glasses for eye protection.

Use safety stands whenever a procedure requires youto be under the vehicle.

Be sure that the ignition switch is always in the OFFposition, unless otherwise required by the procedure.

Set the parking brake when working on the vehicle. If youhave an automatic transmission, set it in PARK unlessinstructed otherwise for a specific service operation. Ifyou have a manual transmission it should be in REVERSE(engine OFF) or NEUTRAL (engine ON) unless instructedotherwise for a specific service operation.

Operate the engine only in a well-ventilated area to avoidthe danger of carbon monoxide.

Keep yourself and your clothing away from moving partswhen the engine is running, especially the fan and belts.

To help prevent serious burns, avoid contact with hotmetal parts such as the radiator, exhaust manifold, tailpipe, catalytic converter and muffler.

Do not smoke while working on the vehicle.

To help avoid injury, always remove rings, watches,loose hanging jewelry, and loose clothing before begin-ning to work on a vehicle. Tie long hair securely behindyour head.

Keep hands and other objects clear of the radiator fanblades. Electric cooling fans can start to operate at anytime by an increase in underhood temperatures, eventhough the ignition is in the OFF position. Therefore,care should be taken to ensure that the electric coolingfan is completely disconnected when working under thehood.

The recommendations and suggestions contained in this manual are made to assist the dealer in improving his dealership partsand/or service department operations. These recommendations and suggestions do not supersede or override the provisions ofthe Warranty and Policy Manual, and in any cases where there may be a conflict, the provisions of the Warranty and Policy Manualshall govern.

The descriptions, testing procedures, and specifications in this handbook were in effect at the time the handbook wasapproved for printing. Ford Motor Company reserves the right to discontinue models at any time, or change specifications,design, or testing procedures without notice and without incurring obligation. Any reference to brand names in this manualis intended merely as an example of the types of tools, lubricants, materials, etc. recommended for use. Equivalents, ifavailable, may be used. The right is reserved to make changes at any time without notice.

DANGER: Exposure to potentially hazardous components may occur if dusts are created during repair of friction compo-nents, such as brake pads and clutch discs. Exposure to excessive amounts of dust may be a potential cancer and lung diseasehazard. Exposure may also cause irritation to skin, eyes, and respiratory tract, may cause allergic reactions, and/or may lead to otherchronic health effects.

Do not breathe dust. Do not use compressed air to blow dust from storage containers or friction components. A high-efficiency(HEPA) vacuum cleaner should be used carefully to remove dust. Adherent dust should be removed with a damp rag.

If inhaled, remove to fresh air. If irritation persists, seek medical attention or advice.

If dust gets in eyes, irrigate under eyelids with water for 15 minutes and seek medical attention.

Copyright © 2007 Ford Motor Company Produced and Coodinated byTechnical Support OperationsFord Customer Service Division

August 2007

Page 4: Manual Transmission/ Transaxle Repair - DealerConnection · MANUAL TRANSMISSION/TRANSAXLE REPAIR INTRODUCTION Manual Transmission/Transaxle Repair Intro - 3 August 2007 Course Requirements

CUSTOMER EXPECTATIONSM

Customer Expectations: Service1. Make it convenient to have my vehicle

serviced at your dealership.

2. The Service Advisor should demonstratea genuine concern for my service needs.

3. Fix it right the first time, on time.

4. Complete servicing my vehicle in atimely and professional manner.

5. Provide me with a clear and thoroughexplanation of the service performed.

6. Call me within a reasonable amount oftime after my service visit to ensure thatI'm completely satisfied.

7. Be responsive to questions or concernsthat I bring to your attention.

Expectation #3

“Fix It Right the First Time, on Time.”Both service advisors and technicians are important players when it comes to Expectation #3.

WhyCustomers tell us “Fixing It Right the First Time, on Time” is one of the reasons they woulddecide to return to a dealer to buy a vehicle and get their vehicles serviced.

Technician TrainingIt is our goal to help the technician acquire all of the skills and knowledge necessary to“Fix it Right the First Time, on Time.” We refer to this as “competency.”

Technician’s RoleAcquire the skills and knowledge for competency in your specialty via:

STST New Model— Web-Based — Web-Based— Instructor Led — Instructor Led

The BenefitsThe successful implementation of expectations means:

— Satisfied customers— Repeat vehicle sales— Repeat service sales— Recognition that Ford and Lincoln/Mercury technicians are “the Best in the Business”

Page 5: Manual Transmission/ Transaxle Repair - DealerConnection · MANUAL TRANSMISSION/TRANSAXLE REPAIR INTRODUCTION Manual Transmission/Transaxle Repair Intro - 3 August 2007 Course Requirements

MANUAL TRANSMISSION/TRANSAXLE REPAIR TABLE OF CONTENTS

Manual Transmission/Transaxle Repair TOC - i August 2007

INTRODUCTION ................................................................................................ INTRO - 1Manual Transmission/Transaxle Repair .................................................................................... Intro - 2

Course Description .............................................................................................................. Intro - 2Course Requirements .......................................................................................................... Intro - 3Course Objectives ............................................................................................................... Intro - 3Course Agenda ................................................................................................................... Intro - 3

LESSON ONE ............................................................................................................1 - 1Prerequisite Review .......................................................................................................................1 - 2

Theory and Operation Questions ..............................................................................................1 - 2Diagnosis Questions ................................................................................................................1 - 3

LESSON ONE WORKSTATIONS ................................................................................1 - 7Workstation 1A T5OD Disassembly ...............................................................................................1 - 8Workstation 2A Disassembly and Assembly of T5OD Transmission Subassemblies...................1 - 10Workstation 3A T5OD Transmission Assembly ............................................................................1 - 12

LESSON TWO ............................................................................................................2 - 1Workstation 1B Clutch Diagnosis and Service ...............................................................................2 - 2Workstation 2B MTX-75 Transaxle Disassembly............................................................................2 - 4Workstation 3B MTX-75 Transaxle Assembly ................................................................................2 - 6

Page 6: Manual Transmission/ Transaxle Repair - DealerConnection · MANUAL TRANSMISSION/TRANSAXLE REPAIR INTRODUCTION Manual Transmission/Transaxle Repair Intro - 3 August 2007 Course Requirements

MANUAL TRANSMISSION/TRANSAXLE REPAIR TABLE OF CONTENTS

Manual Transmission/Transaxle Repair TOC - ii August 2007

Page 7: Manual Transmission/ Transaxle Repair - DealerConnection · MANUAL TRANSMISSION/TRANSAXLE REPAIR INTRODUCTION Manual Transmission/Transaxle Repair Intro - 3 August 2007 Course Requirements

MANUAL TRANSMISSION/TRANSAXLE REPAIR INTRODUCTION

Manual Transmission/Transaxle Repair Intro - 1 August 2007

INTRODUCTION

Page 8: Manual Transmission/ Transaxle Repair - DealerConnection · MANUAL TRANSMISSION/TRANSAXLE REPAIR INTRODUCTION Manual Transmission/Transaxle Repair Intro - 3 August 2007 Course Requirements

MANUAL TRANSMISSION/TRANSAXLE REPAIR INTRODUCTION

Manual Transmission/Transaxle Repair Intro - 2 August 2007

This instructor-led course is part of the Ford Manual Transmission and Drivetrain curriculum. It is a two-day

course facilitated by an instructor. This course is designed to provide hands-on opportunities for technicians to

learn and improve their skills using tools and equipment, and to apply knowledge learned in prerequisite courses.

Each day, you will have multiple opportunities to practice selected skills. The results of your work are recorded

on worksheets.

MANUAL TRANSMISSION/TRANSAXLE REPAIR

Course Description

T5OD Transmission (Left) and MTX-75 Transaxle (Right)

Page 9: Manual Transmission/ Transaxle Repair - DealerConnection · MANUAL TRANSMISSION/TRANSAXLE REPAIR INTRODUCTION Manual Transmission/Transaxle Repair Intro - 3 August 2007 Course Requirements

MANUAL TRANSMISSION/TRANSAXLE REPAIR INTRODUCTION

Manual Transmission/Transaxle Repair Intro - 3 August 2007

Course Requirements

Each technician attending this course is required to pass a combination of hands-on and written

evaluations. These are administered after all lectures, demonstrations and/or practice sessions have been

completed.

� The hands-on evaluation is a pass/fail type. It is conducted with exercises in manual transmission andtransaxle assembly, and covers:

– selected end play measurements to be made during assembly

– service publication navigation

– selected special tool usage

To pass the course, you must demonstrate 100% mastery of the skills covered in the Hands-On Post-Test

exercises AND you must correctly answer at least 80% of the Written Post-Test questions.

Course Objectives

Upon successful completion of this course, you will be able to:

� Explain common manual transmission and transaxle system diagnostic procedures.

� Perform manual transmission and transaxle repairs.

� Perform clutch system diagnosis and service.

Course Agenda

� Introductions

� Prerequisite Review

� WORKSTATIONS

– Rotation 1: T5OD Transmission Disassembly, Subassemblies and Assembly

– Rotation 2: Clutch Diagnosis and Service; MTX-75 Transaxle Disassembly and Assembly

� Workstations Review

� Hands-On and Written Evaluations

Page 10: Manual Transmission/ Transaxle Repair - DealerConnection · MANUAL TRANSMISSION/TRANSAXLE REPAIR INTRODUCTION Manual Transmission/Transaxle Repair Intro - 3 August 2007 Course Requirements

MANUAL TRANSMISSION/TRANSAXLE REPAIR INTRODUCTION

Manual Transmission/Transaxle Repair Intro - 4 August 2007

NOTES:

Page 11: Manual Transmission/ Transaxle Repair - DealerConnection · MANUAL TRANSMISSION/TRANSAXLE REPAIR INTRODUCTION Manual Transmission/Transaxle Repair Intro - 3 August 2007 Course Requirements

LESSON ONE PREREQUISITE REVIEW

Manual Transmission/Transaxle Repair 1 - 1 August 2007

LESSON ONE

Page 12: Manual Transmission/ Transaxle Repair - DealerConnection · MANUAL TRANSMISSION/TRANSAXLE REPAIR INTRODUCTION Manual Transmission/Transaxle Repair Intro - 3 August 2007 Course Requirements

LESSON ONE PREREQUISITE REVIEW

Manual Transmission/Transaxle Repair 1 - 2 August 2007

PREREQUISITE REVIEW

DIRECTIONS: Answer the following questions on manual transmissions, transaxles and clutches.

Questions may be related to theory, operation, diagnosis and service. These will be reviewed in class.

Theory and Operation Questions

1. In a RWD manual transmission, in which direction do the following shafts rotate, relative to the engine, withthe transmission moving in a forward gear?

(Circle one.)

Input shaft: SAME AS ENGINE ROTATION OPPOSITE TO ENGINE ROTATION

Countershaft: SAME AS ENGINE ROTATION OPPOSITE TO ENGINE ROTATION

Output shaft: SAME AS ENGINE ROTATION OPPOSITE TO ENGINE ROTATION

2. Number the following steps 1 through 4, to show the order of the powerflow through a RWDtransmission in Reverse gear.

_______ Countershaft/gear

_______ Output shaft gear

_______ Input shaft gear

_______ Idler gear

3. List some of the reasons a synchronizer is used in a manual transmission or transaxle:

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

Page 13: Manual Transmission/ Transaxle Repair - DealerConnection · MANUAL TRANSMISSION/TRANSAXLE REPAIR INTRODUCTION Manual Transmission/Transaxle Repair Intro - 3 August 2007 Course Requirements

LESSON ONE PREREQUISITE REVIEW

Manual Transmission/Transaxle Repair 1 - 3 August 2007

4. Dampening springs in the clutch disc or flywheel accomplish all of the following EXCEPT:

A. Reduce chatter/shudder during clutch engagement

B. Reduce clutch slippage

C. Reduce NVH

D. Absorb power pulses from the engine

5. What components in the manual transaxle differential assembly allow for wheel speed differences duringcornering?

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

Diagnosis Questions

6. A damaged shift interlock can cause which of the following concerns? (Circle all that apply.)

Locked out of certain gears

Two gears engaged at the same time

Gear clash during shifting

Transmission locked in one gear

Chattering noise in forward gears

Page 14: Manual Transmission/ Transaxle Repair - DealerConnection · MANUAL TRANSMISSION/TRANSAXLE REPAIR INTRODUCTION Manual Transmission/Transaxle Repair Intro - 3 August 2007 Course Requirements

LESSON ONE PREREQUISITE REVIEW

Manual Transmission/Transaxle Repair 1 - 4 August 2007

7. On a rear-wheel drive vehicle, a squealing noise is present when the clutch pedal is depressed and the vehicleis stopped with the transmission in gear. What is the likely cause?

A. Clutch release bearing

B. Pilot bearing

C. Input shaft bearing

D. Countershaft bearing

8. A whining noise is present only while driving with the manual transmission in 2nd gear. List somecomponents that could possibly cause this concern:

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

9. A whining noise is present while driving with the manual transmission in any gear except direct drive. Whichof the following could cause this concern?

A. Pilot bearing

B. Countershaft bearings

C. Input shaft bearing

D. Pocket (input) thrust bearing

Page 15: Manual Transmission/ Transaxle Repair - DealerConnection · MANUAL TRANSMISSION/TRANSAXLE REPAIR INTRODUCTION Manual Transmission/Transaxle Repair Intro - 3 August 2007 Course Requirements

LESSON ONE PREREQUISITE REVIEW

Manual Transmission/Transaxle Repair 1 - 5 August 2007

10. A customer complains of a grinding condition that exists whenever the T5OD manual transmission is shiftedinto Reverse.

Technician A says that the reverse brake ring assembly could cause this concern.

Technician B says that the driver may be shifting into Reverse while the vehicle is moving.

Who is correct?

A. Technician A

B. Technician B

C. Both Technicians

D. Neither Technician

11. While road testing a vehicle with a manual transmission, you verify a customer concern that the transmissionjumps out of gear. List the possible causes of this concern:

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

12. What condition could cause accelerated wear on a shift fork or synchronizer assembly?

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

Page 16: Manual Transmission/ Transaxle Repair - DealerConnection · MANUAL TRANSMISSION/TRANSAXLE REPAIR INTRODUCTION Manual Transmission/Transaxle Repair Intro - 3 August 2007 Course Requirements

LESSON ONE PREREQUISITE REVIEW

Manual Transmission/Transaxle Repair 1 - 6 August 2007

13. What steps are required to properly test for a slipping clutch?

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

What is the condition if the engine:

stalls within 5 seconds after clutch is fully engaged? ________________________________________

does not stall when clutch is fully engaged? _____________________________________________

14. During removal of a manual transaxle, why is a special puller required to remove and install the halfshaftassembly from the wheel ends?

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

15. If a RWD transmission has worn countershaft bearings, a whining or growling noise would become quieter inwhich gear range?

A. Reduction

B. Direct drive

C. Overdrive

D. Reverse

Page 17: Manual Transmission/ Transaxle Repair - DealerConnection · MANUAL TRANSMISSION/TRANSAXLE REPAIR INTRODUCTION Manual Transmission/Transaxle Repair Intro - 3 August 2007 Course Requirements

LESSON ONE WORKSTATIONS

Manual Transmission/Transaxle Repair 1 - 7 August 2007

LESSON ONEWORKSTATIONS

Workstation: Summary:

1A Students use the Workshop Manual and required special tools to disassemble a T5OD

transmission and answer related questions in the worksheet.

2A Students use the Workshop Manual and required special tools to disassemble and assemble

selected T5OD transmission subassemblies and answer related questions in the worksheet.

3A Students use the Workshop Manual and required special tools to assemble a T5OD

transmission, perform all end play measurements, and answer related questions in the

worksheet.

Page 18: Manual Transmission/ Transaxle Repair - DealerConnection · MANUAL TRANSMISSION/TRANSAXLE REPAIR INTRODUCTION Manual Transmission/Transaxle Repair Intro - 3 August 2007 Course Requirements

LESSON ONE WORKSTATION 1A

Manual Transmission/Transaxle Repair 1 - 8 August 2007

WORKSTATION 1AT5OD DISASSEMBLY

DIRECTIONS: Complete Workstation 1A at the bench workstation, using the T5OD transmission, available

hand tools and special service tools, and Workshop Manual.

SUMMARY: For this activity, you will disassemble a T5OD transmission down to its major subassemblies and

perform any necessary inspections required by the Workshop Manual.

� Follow the Mustang Workshop Manual, Section 308-03A, to disassemble the T5OD transmission to its majorsubassemblies. (Use the appropriate model year Workshop Manual for the transmission you have in class.)

� As you perform the disassembly procedures, pay attention to the following questions related to key steps.

1. Can the clutch slave cylinder retaining clip be reused? Why or why not? (Applicable to 2005 MY or newerT5OD transmissions.)

_______________________________________________________________________________________

2. Upon mounting the transmission to the holding fixture, in what position must the transmission gearshift leverbe placed?

_______________________________________________________________________________________

3. The gearshift offset lever cannot be removed while the transmission extension housing is bolted in place.Why?

_______________________________________________________________________________________

_______________________________________________________________________________________

4. Why are two of the transmission cover bolts larger than the others?

_______________________________________________________________________________________

5. Why is it important to NOT pry against machined sealing surfaces?

_______________________________________________________________________________________

_______________________________________________________________________________________

6. Why is it important to support the reverse gear shift rail with a block of wood?

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

Follow Worksheet 2A to disassemble and assemble some of the above subassemblies.

Continued on next page.

Page 19: Manual Transmission/ Transaxle Repair - DealerConnection · MANUAL TRANSMISSION/TRANSAXLE REPAIR INTRODUCTION Manual Transmission/Transaxle Repair Intro - 3 August 2007 Course Requirements

LESSON ONE WORKSTATION 1A

Manual Transmission/Transaxle Repair 1 - 9 August 2007

7. Why does the Workshop Manual tell you to note the position of the reverse gearshift lever/shift fork assemblyand reverse positioning spring?

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

8. Can the countershaft bearing retainer be reused? Why or why not?

_______________________________________________________________________________________

_______________________________________________________________________________________

9. What is the purpose of using tool 204-069 and 205-D064 during disassembly?

_______________________________________________________________________________________

10. Upon completion of the disassembly procedures in the Workshop Manual, what subassemblies are left?

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

Page 20: Manual Transmission/ Transaxle Repair - DealerConnection · MANUAL TRANSMISSION/TRANSAXLE REPAIR INTRODUCTION Manual Transmission/Transaxle Repair Intro - 3 August 2007 Course Requirements

LESSON ONE WORKSTATION 2A

Manual Transmission/Transaxle Repair 1 - 10 August 2007

WORKSTATION 2ADISASSEMBLY AND ASSEMBLY OF T5OD TRANSMISSION SUBASSEMBLIES

DIRECTIONS: Complete Workstation 2A at the bench workstation, using the T5OD transmission, available

hand tools and special service tools, and Workshop Manual.

SUMMARY: For this activity, you will disassemble and assemble the input shaft, output shaft and one

synchronizer from a T5OD transmission and perform any necessary inspections required by the Workshop

Manual.

� Follow the Mustang Workshop Manual, Section 308-03A, to disassemble and assemble the T5ODtransmission subassemblies. (Use the appropriate model year Workshop Manual for the transmission youhave in class.)

� As you perform the disassembly and assembly procedures, pay attention to the following questions related tokey steps.

Input Shaft

1. Inspect the input shaft splines for wear or damage. Why is it important to do this?

_______________________________________________________________________________________

_______________________________________________________________________________________

2. For this activity, DO NOT remove the input shaft seal. If removed, could the input shaft seal be reused?Why or why not?

_______________________________________________________________________________________

3. What condition would likely be present if the input shaft needle bearing and spacer are worn or scored?

_______________________________________________________________________________________

4. Are the selective shims initially installed during assembly of the T5OD input shaft subassembly? Why orwhy not?

_______________________________________________________________________________________

Output Shaft

NOTE: During disassembly, inspect bearings, needle bearings, and gears for any signs of wear or damage.

5. Be sure to remove the ball under the inner race for the 1st speed gear before removing the 1st synchronizercones and blocking ring. What is the purpose of this ball?

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

Continued on next page.

Page 21: Manual Transmission/ Transaxle Repair - DealerConnection · MANUAL TRANSMISSION/TRANSAXLE REPAIR INTRODUCTION Manual Transmission/Transaxle Repair Intro - 3 August 2007 Course Requirements

LESSON ONE WORKSTATION 2A

Manual Transmission/Transaxle Repair 1 - 11 August 2007

Synchronizer

6. Before removing a synchronizer from the output shaft, use a feeler gauge to measure the wear gap clearancebetween the synchronizer blocking ring and the clutching teeth on the gear. Enter the value below:

_______________________________________________________________________________________

If the gap is below __________ millimeters or __________ inches, replace the appropriate blocking ring.

7. Are synchronizer components interchangeable? Why or why not?

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

8. How are the springs for the synchro keys installed?

_______________________________________________________________________________________

_______________________________________________________________________________________

9. Why is proper clocking/timing of the synchronizer keys critical during assembly?

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

NOTE: Assemble the synchronizer, install it on the Output Shaft and then finish assembly of the Output Shaft.

Page 22: Manual Transmission/ Transaxle Repair - DealerConnection · MANUAL TRANSMISSION/TRANSAXLE REPAIR INTRODUCTION Manual Transmission/Transaxle Repair Intro - 3 August 2007 Course Requirements

LESSON ONE WORKSTATION 3A

Manual Transmission/Transaxle Repair 1 - 12 August 2007

WORKSTATION 3AT5OD TRANSMISSION ASSEMBLY

DIRECTIONS: Complete Workstation 3A at the bench workstation, using the T5OD transmission, available

hand tools and special service tools, and Workshop Manual.

SUMMARY: For this activity, you will assemble a T5OD transmission, performing any necessary measurements

and inspections required by the Workshop Manual.

� Follow the Mustang Service Information, Section 308-03A, to assemble the T5OD transmission and performany necessary inspections and measurements. (Use the appropriate model year Workshop Manual for thetransmission you have in class.)

� If adjustments are required, identify the correct size select-fit part that is needed.

1. What are the instructions for soaking the blocking rings prior to assembly?

_______________________________________________________________________________________

2. Use a new bearing retainer plate to obtain end play measurements. After gauging, install the original bearingretainer plate. Using the dial indicator to measure countershaft bearing gear end play.

Your measurement: __________________________

Specification: __________________________________________________

What size shim is needed to bring the end play within specifications? __________________________

3. When installing the reverse idler gear and bushing in the T5OD case, the shift lever groove must face toward:

_______________________________________________________________________________________

4. How can you tell if the reverse positioning spring is installed correctly?

_______________________________________________________________________________________

5. When installing the input shaft bearing retainer, the notch on the circular mount MUST face _____________,

and the slot must face ________________.

6. How much silicone rubber sealant (TA-32) must be applied to the input shaft bearing retainer?

_______________________________________________________________________________________

7. What would be the result if too much sealant is applied?

_______________________________________________________________________________________

_______________________________________________________________________________________

8. To prevent component damage, the alignment tab on the reverse brake ring must align with:

_______________________________________________________________________________________

9. Using the dial indicator, measure output shaft end play.

Your measurement: ___________________________________________________

Specification: ___________________________________________________

What size shim is needed to bring the end play within specification? __________________________

Page 23: Manual Transmission/ Transaxle Repair - DealerConnection · MANUAL TRANSMISSION/TRANSAXLE REPAIR INTRODUCTION Manual Transmission/Transaxle Repair Intro - 3 August 2007 Course Requirements

LESSON TWO WORKSTATIONS

Manual Transmission/Transaxle Repair 2 - 1 August 2007

LESSON TWOWORKSTATIONS

Workstation: Summary:

1B Students use the Workshop Manual, available components and a clutch system buck to

perform selected inspection, diagnosis and service tasks, including hydraulic clutch bleeding.

2B Students use the Workshop Manual and required special tools to disassemble an MTX-75

transaxle and answer additional questions on the differential and other subassemblies.

3B Students use the Workshop Manual and required special tools to assemble an MTX-75

transaxle and perform all end play measurements.

Page 24: Manual Transmission/ Transaxle Repair - DealerConnection · MANUAL TRANSMISSION/TRANSAXLE REPAIR INTRODUCTION Manual Transmission/Transaxle Repair Intro - 3 August 2007 Course Requirements

LESSON TWO WORKSTATION 1B

Manual Transmission/Transaxle Repair 2 - 2 August 2007

WORKSTATION 1BCLUTCH DIAGNOSIS AND SERVICE

DIRECTIONS: For this activity, you will use components and a mock-up of the hydraulic clutch system to

perform hydraulic clutch bleeding and selected clutch component inspections/tests. Refer to the 2006 Ranger

Workshop Manual, Section 308-00, and complete the following worksheet questions during the activities.

1. What tests are available for the clutch pressure plate?

_______________________________________________________________________________________

_______________________________________________________________________________________

2. What symptoms may be present if the pressure plate adjuster is misadjusted or damaged?

_______________________________________________________________________________________

_______________________________________________________________________________________

3. What tests are available for the clutch disc?

_______________________________________________________________________________________

_______________________________________________________________________________________

� Refer to the 2006 Ranger Workshop Manual, Section 308-00, Pinpoint Test D. Start at Step D1 and workthrough this Pinpoint Test to perform:

– Visual Inspections

– Hydraulic System Internal Check

– Clutch Pedal Reserve

– Clutch Pedal Free Play Check

– Clutch Hydraulic System Bleeding

4. If you were performing a Clutch Pedal Reserve Check on an actual vehicle, what are some of the vehiclepreparation requirements that must be done first?

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

5. When the above requirements have been met, how is the Clutch Pedal Reserve check performed?

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

Continued on next page.

Page 25: Manual Transmission/ Transaxle Repair - DealerConnection · MANUAL TRANSMISSION/TRANSAXLE REPAIR INTRODUCTION Manual Transmission/Transaxle Repair Intro - 3 August 2007 Course Requirements

LESSON TWO WORKSTATION 1B

Manual Transmission/Transaxle Repair 2 - 3 August 2007

6. What distance is being measured in the Clutch Pedal Free Play Check?

_______________________________________________________________________________________

_______________________________________________________________________________________

7. Besides opening the system for service, how else can air get into the clutch hydraulic system?

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

8. What conditions can be caused by air in the clutch hydraulic system?

_______________________________________________________________________________________

_______________________________________________________________________________________

9. What should an assistant do just before you loosen the bleeder screw to let air escape the clutch system?

_______________________________________________________________________________________

_______________________________________________________________________________________

INSTRUCTOR DEMO: Ask your instructor to demonstrate to you how to “reset” an adjustable pressure plate.

Refer to the 2006 Ranger Workshop Manual, Section 308-01, and answer the following questions:

10. During clutch disc and pressure plate installation, what alignment tool is required according to the WorkshopManual?

_______________________________________________________________________________________

11. What is the maximum specification for tension spring adjustment when resetting the clutch pressure plate?

_______________________________________________________________________________________

12. What steps must be taken to reset the pressure plate?

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

13. If the original clutch pressure plate or flywheel are to be reused, what are you to do?

_______________________________________________________________________________________

14. What is the difference between the instructor’s demonstration of the adjustable pressure plate and theadjustment procedure in the Workshop Manual?

_______________________________________________________________________________________

15. What were the press target areas on the pressure plate that are critical during the Instructor Demo on thepressure plate?

_______________________________________________________________________________________

_______________________________________________________________________________________

Page 26: Manual Transmission/ Transaxle Repair - DealerConnection · MANUAL TRANSMISSION/TRANSAXLE REPAIR INTRODUCTION Manual Transmission/Transaxle Repair Intro - 3 August 2007 Course Requirements

LESSON TWO WORKSTATION 2B

Manual Transmission/Transaxle Repair 2 - 4 August 2007

WORKSTATION 2BMTX-75 TRANSAXLE DISASSEMBLY

DIRECTIONS: Complete Workstation 2B at the bench workstation, using the MTX-75 transaxle, available hand

tools and special service tools, and Workshop Manual.

SUMMARY: For this activity, you will disassemble an MTX-75 transaxle down to its major subassemblies,

performing any necessary inspections required by the 2006 Workshop Manual along the way.

� Follow the Focus Service Information, Section 308-03, to disassemble the MTX-75 transaxle to its majorsubassemblies. (Use the appropriate model year Workshop Manual for the transmission you have in class.)

� As you perform the disassembly procedures, pay attention to the following questions related to key steps.

1. Is the release bearing assembly reusable? Why or why not?

_______________________________________________________________________________________

_______________________________________________________________________________________

2. To remove the shift tower assembly, in what position must the gearshift lever be placed?

_______________________________________________________________________________________

3. How are the input shaft and output shaft assemblies removed from the transaxle case?

_______________________________________________________________________________________

_______________________________________________________________________________________

4. What does the Workshop Manual recommend to assist in the removal of the differential, output shaft andinput shaft bearing races with the 308-001 slide hammer and adapter?

_______________________________________________________________________________________

5. When would you need to remove the reverse idler gear shaft from the case?

_______________________________________________________________________________________

6. Upon completion of the MTX-75 disassembly process, what subassemblies are left?

_______________________________________________________________________________________

Refer to the MTX-75 Subassembly procedures in the Workshop Manual to answer Questions 7-9.

NOTE: DO NOT disassemble the Input Shaft or the Output Shaft subassemblies.

7. When servicing the input shaft and output shaft assemblies, can needle bearings and synchronizer rings bereused?

_______________________________________________________________________________________

8. If removed during disassembly, can input shaft, output shaft or differential bearings be reused? Why or whynot?

_______________________________________________________________________________________

_______________________________________________________________________________________

Continued on next page.

Page 27: Manual Transmission/ Transaxle Repair - DealerConnection · MANUAL TRANSMISSION/TRANSAXLE REPAIR INTRODUCTION Manual Transmission/Transaxle Repair Intro - 3 August 2007 Course Requirements

LESSON TWO WORKSTATION 2B

Manual Transmission/Transaxle Repair 2 - 5 August 2007

9. What can be replaced on the differential assembly, using the Workshop Manual?

_______________________________________________________________________________________

NOTE: The following questions refer ONLY to the disassembly, inspection and reassembly of the 5th/

Reverse synchronizer using the Output Shaft Subassembly section 308-03 of the 2006 Focus

Workshop Manual. Each student MUST disassemble and reassemble the synchronizer. Upon

completion, the instructor must sign-off in the space provided below.

10. How should the output shaft bearing be removed?

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

11. When removing the 5th/reverse gear synchronizer assembly, what parts are to be discarded?

_______________________________________________________________________________________

12. According to the Workshop Manual, why would a synchronizer need to be replaced?

_______________________________________________________________________________________

13. According to the Workshop Manual, what is a recommended aid for proper synchronizer assembly?

_______________________________________________________________________________________

_______________________________________________________________________________________

Instructor Sign-off: _______________________

Page 28: Manual Transmission/ Transaxle Repair - DealerConnection · MANUAL TRANSMISSION/TRANSAXLE REPAIR INTRODUCTION Manual Transmission/Transaxle Repair Intro - 3 August 2007 Course Requirements

LESSON TWO WORKSTATION 3B

Manual Transmission/Transaxle Repair 2 - 6 August 2007

WORKSTATION 3BMTX-75 TRANSAXLE ASSEMBLY

DIRECTIONS: Complete Workstation 3B at the bench workstation, using the MTX-75 transaxle, available hand

tools and special service tools, and Workshop Manual.

SUMMARY: For this activity, you will assemble an MTX-75 transaxle, performing any necessary measurements

and inspections required by the Workshop Manual.

� Follow the Focus Service Information, Section 308-03, to assemble the MTX-75 transaxle and perform anynecessary inspections and measurements. (Use the appropriate model year Workshop Manual for thetransmission you have in class.)

� If adjustments are required, identify the correct size select-fit part that is needed.

1. When is it necessary for you to check input shaft endplay, output shaft and differential preloads?

_______________________________________________________________________________________

2. If new input shaft, output shaft and/or differential bearings are installed, what else must be done?

_______________________________________________________________________________________

3. List the nominal shim sizes required when initially installing the bearings on the clutch side.

Input shaft (Part No. F5RZ-7L172-DA): __________ mm (__________) inches

Output shaft (Part No. F5RZ-7N135-AA): __________ mm (__________) inches

Differential (Part No. 91ZZ-4067-XA): __________ mm (__________) inches

4. What is the purpose of Input Shaft Socket 308-224?

_______________________________________________________________________________________

5. Using the dial indicator and the Workshop Manual procedures, measure end play/preload per the table belowand calculate the shim required. Enter your answers in the appropriate spaces.

6. How can you tell if the shift rail assemblies are installed correctly?

_______________________________________________________________________________________

7. After applying sealant to the case mating surface, attaching bolts must be installed and tightened within

__________ minutes. Sealer cures rapidly.

ssenkcihTmihSderiuqeR57-XTM

epyT )mm(tfahStupnI )mm(tfahStuptuO )mm(laitnereffiD

smihsgnirusaeM 00.1 00.1 01.1

taolfdnedenimreteD + _________ + _________ + _________

erugifdaolerP 31.0+ 33.0+

taolfdnE 50.0-

ssenkcihtmihsderiuqeR = _________ = _________ = _________

elbaliavasmihS )spetsmm10.0ni(17.1-51.1 )spetsmm20.0ni(19.1-13.1 )spetsmm50.0ni(02.2-04.1