308-03A Câmbio manual MT75 (5 marchas)

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-1 308-03A-1 Manual Transmission - MT75 . SECTION 308-03A Manual Transmission/Transaxle ² Vehicles With: 5-Speed Manual Transmission - MT75 VEHICLE APPLICATION: 2011.50 Ranger CONTENTS SPECIFICATIONS Specifications...................................................................................................................... DESCRIPTION AND OPERATION Manual Transmission.......................................................................................................... Power Flow......................................................................................................................... GENERAL PROCEDURES Transmission Draining and Filling....................................................................................... REMOVAL Transmission – 2WD......................................................................................................... Transmission – 4WD......................................................................................................... DISASSEMBLY Transmission...................................................................................................................... DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Input Shaft.......................................................................................................................... Output Shaft........................................................................................................................ Countershaft....................................................................................................................... Reverse Idler Gear............................................................................................................. Synchronizers..................................................................................................................... Gearshift Control Shaft....................................................................................................... ASSEMBLY Transmission...................................................................................................................... INSTALLATION Transmission – 2WD......................................................................................................... Transmission – 4WD......................................................................................................... PAGE 308-03A-2 308-03A-3 308-03A-10 308-03A-16 308-03A-17 308-03A-21 308-03A-26 308-03A-35 308-03A-36 308-03A-40 308-03A-41 308-03A-42 308-03A-43 308-03A-44 308-03A-56 308-03A-60

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-2 308-03A-2 Manual Transmission - MT75 SPECIFICATIONS Lubricants, Fluids, Sealers and Adhesives Item Manual transmission fluid Sealant Grease Thread-locking compound Capacities MT75 transmission Torque Specifications Description Selector gate retaining bolts Transmission retaining bolts Reversing lamp switch Transmission output shaft flange retaining nut Oil drain plug Oil fill plug Vehicle speed sensor (VSS) Specification WSD-M2C200-C WSK-M2G348-A8 / WSS-M2G348-A10 ESD-M1C220-A SDM-4G9107-A Litres 1.7 Nm lb-ft lb-in 10 - 89 50 37 - 20 15 - 200 148 - 50 37 - 35 26 - 10 - 89

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-3 308-03A-3 Manual Transmission - MT75 DESCRIPTION AND OPERATION Manual Transmission Transmission Overview 3 2 1 ELE0010443 Item Part Description Number 1 Mainshaft – Input shaft/Output shaft 2 Transmission front case 3 Shifter fork third/fourth gear 4 Selector shaft 4 5 6 7 8 Item Part Description Number 5 Transmission rear case 6 Output drive flange 7 Reverse gear idler 8 Counter shaft

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-4 308-03A-4 Manual Transmission - MT75 DESCRIPTION AND OPERATION The MT - 75 manual transmission is a “ three - shaft transmission". MT - 75 means: œ M: Manual. œ T: Transmission œ 75: Distance between main shaft and counter shaft in mm. The aluminum transmission housing consists of two closed sections. The reinforcing ribs on the transmission housing have been revised to reduce noise and vibration. Mainshaft and Counter Shaft 3 2 1 ELE0010444 Item Part Description Number 1 Input shaft 2 Selector fork third/fourth gear 3 Selector fork fifth/reverse gear With the “ three - shaft transmission", all the gears are in permanent mesh. In each gear the required transmission ratio is achieved by means of a pair of gears. When the reverse gear is selected, the direction of the output shaft is changed by an idler gear. The input and output shafts turn on taper roller bearings. All the gears, including reverse, are bevel - cut, synchronized and turn on needle roller bearings. 4 5 6 Item Part Description Number 4 Output shaft 5 Reverse gear idler 6 Counter shaft

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-5 308-03A-5 Manual Transmission - MT75 DESCRIPTION AND OPERATION Input shaft 2 1 ELE0010445 Item Part Description Number 1 Input shaft 2 Driving gear for counter shaft 4 3 Item Part Description Number 3 Fourth gear synchronizer teeth 4 Output shaft locating bearing

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-6 308-03A-6 Manual Transmission - MT75 DESCRIPTION AND OPERATION Mainshaft (left - hand side shown) 1 2 7 8 9 13 14 15 16 ELE0010447 Item Part Description Number 1 Output shaft 2 Needle roller bearing 3 Gear wheel first gear 4 Synchronizer ring first gear 5 Synchronizer clutch first/second gear 6 Synchronizer ring second gear 3 4 5 6 10 11 12 Item Part Description Number 7 Snap ring 8 Needle roller bearing Gear wheel second gear 10 Inner race third gear needle roller bearing 11 Neeedle roller bearing 12 Gear wheel third gear

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-7 308-03A-7 Manual Transmission - MT75 DESCRIPTION AND OPERATION Item Part Description Number 13 Synchronizer ring third gear 14 Synchronizer clutch third/fourth gear Mainshaft (right - hand side shown) 1 5 4 ELE0010446 Item Part Description Number 1 Output shaft 2 Needle roller bearing Item Part Description Number 15 Synchronizer ring fourth gear 16 Snap ring 3 2 9 8 7 6 Item Part Description Number 3 Reverse gear wheel 4 Synchronizer ring reverse gear

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-8 308-03A-8 Manual Transmission - MT75 DESCRIPTION AND OPERATION Item Part Description Number 5 Synchronizer clutch fifth/reverse gear 6 Synchronizer ring fifth gear 7 Snap ring Countershaft 1 ELE0010448 Item Part Description Number 1 Inner race 2 Countershaft Item Part Description Number 8 Needle roller bearing Gear wheel fifth gear 10 Taper roller bearing 2 1

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A- 308-03A- Manual Transmission - MT75 DESCRIPTION AND OPERATION Reverse gear idler 4 3 1 ELE0010449 Item Part Description Number 1 Reverse gear idler shaft mounting 2 Roll pin 5 2 Item Part Description Number 3 Reverse gear idler 4 Needle roller bearing 5 Reverse gear idler shaft

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-10 308-03A-10 Manual Transmission - MT75 DESCRIPTION AND OPERATION Power Flow First gear 2 1 ELE0010452 Item Part Description Number 1 Input shaft 2 Driving gear for countershaft 3 Gear wheel fist gear 3 4 6 5 Item Part Description Number 4 Output shaft 5 Counter shaft 6 Synchonizer clutch first/second gear

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-11 308-03A-11 Manual Transmission - MT75 DESCRIPTION AND OPERATION Second gear 2 1 ELE0010453 Item Part Description Number 1 Input shaft 2 Driving gear for countershaft 3 Gear wheel second gear 3 4 5 6 Item Part Description Number 4 Synchonizer clutch first/second gear 5 Output shaft 6 Counter shaft

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-12 308-03A-12 Manual Transmission - MT75 DESCRIPTION AND OPERATION Third gear 2 1 ELE0010454 Item Part Description Number 1 Input shaft 2 Driving gear for countershaft 3 Synchronizer clutch first/second gear 3 4 5 6 Item Part Description Number 4 Gear wheel second gear 5 Output shaft 6 Counter shaft

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-13 308-03A-13 Manual Transmission - MT75 DESCRIPTION AND OPERATION Fourth gear 1 ELE0010455 Item Part Description Number 1 Input shaft 2 Output shaft 2

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-14 308-03A-14 Manual Transmission - MT75 DESCRIPTION AND OPERATION Fifth gear 2 1 ELE0010456 Item Part Description Number 1 Input shaft 2 Driving gear for countershaft 3 Synchronizer clutch fifth/reverse gear 3 4 5 6 Item Part Description Number 4 Gerar wheel fifth gear 5 Output shaft 6 Counter shaft

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-15 308-03A-15 Manual Transmission - MT75 DESCRIPTION AND OPERATION Reverse gear 2 1 ELE0010457 Item Part Description Number 1 Input shaft 2 Driving gear for countershaft 3 Gear wheel reverse gear 4 Synchronizer clutch fifth/reverse gear 5 Output shaft 6 Input shaft 3 4 5 6

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-16 308-03A-16 Manual Transmission - MT75 GENERAL PROCEDURES Transmission Draining and Filling 1. Information not available at this time.

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-17 308-03A-17 Manual Transmission - MT75 REMOVAL Transmission – 2WD Removal General Equipment Transmission Jack 1. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures). 2. Refer to: Floor Console - Single Cab (501-12 Instrument Panel and Console, Removal and Installation). Refer to: Floor Console - Double Cab (501-12 Instrument Panel and Console, Removal and Installation). 3. E132693 4. Refer to: Catalytic Converter (309-00 Exhaust System - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 5. Refer to: Jacking (100-02 Jacking and Lifting, Description and Operation). Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation). 6. Refer to: Driveshaft - 2WD (205-01 Driveshaft, Removal and Installation). 7. x2 x2 E132694 8. x2 x2 E132695

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-18 308-03A-18 Manual Transmission - MT75 REMOVAL 9. NOTE: Cap the fluid line E132696 Vehicles with 2.5L engine 10. E132697 11. x2 E132698 12. E132504 All vehicles 13. E132699 14. x2 E134598

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-19 308-03A-19 Manual Transmission - MT75 REMOVAL 15.General Equipment: Transmission Jack E128845 x4 x4 x4 x4 E134599 16.

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-20 308-03A-20 Manual Transmission - MT75 REMOVAL 17. E134600 18. 2 1 x2 E134601 19. x3 E132702 20. x2 x4 E134602

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-21 308-03A-21 Manual Transmission - MT75 REMOVAL Transmission – 4WD Removal General Equipment Transmission Jack 1. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures). 2. Refer to: Floor Console - Single Cab (501-12 Instrument Panel and Console, Removal and Installation). Refer to: Floor Console - Double Cab (501-12 Instrument Panel and Console, Removal and Installation). 3. E132693 4. Refer to: Catalytic Converter (309-00 Exhaust System - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 5. Refer to: Jacking (100-02 Jacking and Lifting, Description and Operation). Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation). 6. Refer to: Driveshaft - 4WD (205-01 Driveshaft, Removal and Installation). Refer to: Front Driveshaft - 4WD (205-01 Driveshaft, Removal and Installation). 7. x2 x2 E132694 8. x2 x2 E132695

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-22 308-03A-22 Manual Transmission - MT75 REMOVAL 9. NOTE: Cap the fluid line E132696 Vehicles with 2.5L engine 10. E132697 11. x2 E132698 12. E132504 All vehicles 13. E132699 14. x4 E129203

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-23 308-03A-23 Manual Transmission - MT75 REMOVAL 15. x4 x4 E132700 x4 E132455 16.General Equipment: Transmission Jack E128845 17.

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-24 308-03A-24 Manual Transmission - MT75 REMOVAL 18. x3 E132702 19. x2 x4 E132701 20. E132703 21. x4 E132704

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-25 308-03A-25 Manual Transmission - MT75 REMOVAL 22. x2 x2 E132705

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-26 308-03A-26 Manual Transmission - MT75 DISASSEMBLY Transmission Special Tool(s) Installer, Differential Bearing 205-062 (15-025A) 15025A Flange Holding Wrench, Universal 205-072 (15-030A) 15030A Remover, Drive Pinion Oil Seal 205-078 (15-048) 15048 Remover, Bearing/Gear 205-310 (15-091) T115091 Remover, Bearing/Gear 205-311 (15-092) 15092 Remover, Crankshaft Pilot Bearing 303-078 (21-036A) 21036A Special Tool(s) Remover, Crankshaft Pilot Bearing 303-079 (21-037B) 21037B Remover, Oil Seal 303-112 (21-051) 21051 Aligner, Clutch Plate 303-173 (21-103A) 21103A Mounting Stand 303-435 (21-187) 21187 Socket, Guide Sleeve 308-109 (16-040A) PZ16040A Remover/Installer, Front Housing 308-110 (16-041) 16041

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-27 308-03A-27 Manual Transmission - MT75 DISASSEMBLY Special Tool(s) Mounting Bracket for 303-435 308-114 (16-045) 16045 Mounting Brackets for 308-114 308-114-01 (16-045-01) 30811401 Remover, Slider 308-652 E77040 Disassembly All vehicles NOTE: All the bearings are paired and must not be mixed. 1. Remove the external gearshift control cover. E91969 2. Detach the external gearshift control assembly. 1. Remove the nut. 2. Remove the bolts. 2 1 2 E73383 3. Using the special tool, detach the shifter shaft connector. ‡ Remove the external gearshift control assembly. 308-652 308-652 E92145 Vehicles with tachograph 4. Remove the tachograph sensor. ELE0019852 All vehicles 5. Drain the transmission. ‡ Remove the drain plug.

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-28 308-03A-28 Manual Transmission - MT75 DISASSEMBLY ‡ Allow the oil to drain into a suitable container. ELE0012575 6. Remove the vehicle speed sensor (VSS). 8 Nm E92149 7. Mount the transmission on the mounting stand. ‡ Remove the transmission housing retaining bolt. 303-435 308-144-01 308-114 ELE0012576 8. Remove the clutch release bearing and the clutch release lever. ELE0012577 9. Using the special tool, remove the output shaft flange retaining nut. ‡ Discard the nut. 205-072 ELE0012578 10. Using the special tools, remove the output shaft flange. ‡ Remove the splash shield. 205-310 205-311 ELE0012579

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-29 308-03A-29 Manual Transmission - MT75 DISASSEMBLY 11. Using the special tool, remove the output shaft oil seal. 303-112 ELE0012580 12. Remove the VSS ring. ELE0012581 13. Using the special tool, remove the input shaft guide sleeve. 1. Remove the bearing retainer locking plate. 2. Install the special tool and remove the guide sleeve. 2 308-109 ELE0012582 14. Disassemble the input shaft guide sleeve. 1. Remove the oil seal. 2. Remove the thrust washer. 3. Remove the O-ring seal. 2 1 3 ELE0012583 15. Remove the countershaft bearing. 1. Remove the bearing retainer. 2. Remove the circlip. 2 1 ELE0012584 16. Remove the selector interlock mechanism. ELE0012585

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-30 308-03A-30 Manual Transmission - MT75 DISASSEMBLY 17. Remove the selector shaft locking plate bolt. ELE0019848 18. Loosen and remove the reverse gear idler shaft retaining bolts. 1. Loosen the retaining bolt. 2. Remove the retaining bolt. 2 1 ELE0020641 19. Remove the reversing lamp switch. ELE0012586 20. Remove the transmission housing retaining bolts (nine bolts). ELE0012587 21. CAUTIONS: Do not remove the housing locating dowels. Only apply leverage to the reinforcement ribs. Using a suitable lever, separate the two halves of the transmission housing. ELE0012589 22. CAUTION: Do not apply excessive pressure to the input shaft. This may cause damage to the fourth gear synchronizer ring. NOTE: Hold the special tool with a drift.

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-31 308-03A-31 Manual Transmission - MT75 DISASSEMBLY Using the special tool, remove the transmission front housing. 308-110 ELE0012588 23. Remove the third and fourth gear selector fork. 1. Remove the auxiliary selector shaft. 2. Remove the selector fork. 1 2 D1601161 24. Remove the reverse gear idler shaft rear retaining bolt. ELE0019846 25. Remove the magnetic disc. ELE0019847 26. Remove the transmission from the mounting stand. 27. CAUTIONS: Move the main selector shaft to the NEUTRAL position. Failure to follow this instruction may result in damage to the shift finger. Make sure that no component falls off during removal. Using a hydraulic press and press out the output shaft. Avoid the output shaft, input

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-32 308-03A-32 Manual Transmission - MT75 DISASSEMBLY shaft, reverse gear and selector mechanism from falling down. X2 2 X 2 E107983 28. Mount the transmission on the mounting stand. 29. Remove the mainshaft and countershaft assembly, the main selector shaft and the selector fork. ELE0013032 30. Remove the countershaft rear bearing rollers. ELE0012592

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-33 308-03A-33 Manual Transmission - MT75 DISASSEMBLY 31. Using the special tool, remove the countershaft rear bearing. 205-078 ELE0012593 32. NOTE: Only remove the selector gate if it is damaged. Remove the selector gate. ELE0012595 33. Using the special tool, remove the main selector shaft bearing and oil seal. 303-173 D1601169 34. Remove the output shaft bearing retaining bolts. D1601167 35. Using a length of suitable tube, remove the output shaft bearing. D161171 36. Using the special tools and a 63 mm spacer, remove the main selector shaft bearing. 303-079 303-078 D1601172

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-34 308-03A-34 Manual Transmission - MT75 DISASSEMBLY 37. Using a length of suitable tube, remove the input shaft bearing. ELE0012597 38. CAUTION: Do not damage the thread in the transmission housing. Using the special tool, remove the countershaft front bearing. 205-062 ELE0012598

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-35 308-03A-35 Manual Transmission - MT75 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Input Shaft Disassembly 1. CAUTION: Handle the synchronizer ring and synchronizer cone with care. Remove the input shaft with the fourth gear synchronizer ring from the output shaft. ‡ Remove the output shaft locating bearing. ELE0010466 Assembly 1. Carefully clean and check all parts and assemble the parts in reverse order.

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-36 308-03A-36 Manual Transmission - MT75 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Output Shaft Special Tool(s) Remover, Mainshaft Needle Bearing Sleeve 308 - 191 (16 - 056) 16056 General Equipment Hot air gun Materials Name Specification Manual transmission WSD - M2C200 - C fluid Disassembly 1. CAUTION: Mark the position of the synchronizer rings in relation to the synchronizer units to aid installation. Remove the input shaft and fourth gear synchronizer ring from the output shaft. ‡ Remove the output shaft locating bearing. ELE0010466 2. Remove the fifth gear wheel and synchronizer ring from the output shaft. 1. Remove the gear wheel. 2. Remove the gear synchronizer ring. 3. Remove the needle roller bearing. 1 2 3 JI601180 3. WARNING: Do not allow the synchronizers to fall apart. Failure to follow these instructions may result in personal injury. CAUTION: Use soft jaws for all operations in a vise. NOTE: Clamp the output shaft in a vise with the output end. Remove the third/fourth gear synchronizer unit together with the third gear wheel. 1. Remove the circlip. 2. Third/fourth gear synchronizer. 3. Needle roller bearing. 4. Third gear wheel. 1 2 4 3 ELE0011323 4. Using the special tool, remove the third gear bearing ring.

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-37 308-03A-37 Manual Transmission - MT75 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES ‡ Locate the special tool in the recesses off the bearing ring. 308-191 ELE0011322 5. NOTE: Mark the position of the second gear wheel in relation to the synchronizer ring to aid installation. Remove the second gear wheel, the needle roller bearing and synchronizer ring. ELE0011322 6. NOTE: Mark the position of the shift ring in relation to the first gear wheel to aid installation.. Components are paired. NOTE: Remove the circlip. Remove the first/second gear synchronizer and the first gear wheel. 1. First/second gear synchronizer. 2. First gear wheel. 3. Needle roller bearing. 1 2 3 S1601195 7. NOTE: Mark the position of the shift ring in relation to the reverse gear wheel to aid installation. Components are paired. NOTE: Clamp the output shaft the other way round in the vise. NOTE: Remove the circlip. Remove the fifth/reverse gear synchronizer, the reverse gear wheel and needle roller bearing. 1. Fifth/reverse gear synchronizer. 2. Reverse gear wheel. 3. Needle roller bearing. 1 2 3 ELE0011333 Assembly 1. Carefully clean and check all sliding parts and lubricate the synchronizer rings with Manual transmission fluid before assembly. 2. Install the needle roller bearing, reverse gear wheel and synchronizer unit. 1. Install the reverse gear wheel. 2. Install the synchronizer.

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-38 308-03A-38 Manual Transmission - MT75 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES 3. Install the snap ring. 3 2 1 ELJ1601694 3. Install the first/second gear synchronizer unit. 1. Install the needle roller bearing. 2. Install the gear wheel. 3. Install the synchronizer unit. ‡ Install the circlip. 3 2 1 ELJ1601686 4. Install the synchronizer ring, needle roller bearing and second gear wheel. 1. Install the needle roller bearing. 2. Install the synchronizer ring. 3. Install the gear wheel. 3 2 1 ELJ1601684 5. NOTE: Slide the inner bearing ring onto the output shaft as far as the shoulder. NOTE: Install a new inner bearing ring and needle bearing. Using a hot air gun heat the inner bearing ring to approximately 100 ° C and install it. ELJ1601683 6. NOTE: Install the synchronizer with the small collar upwards. NOTE: Install the needle roller bearing. Install the third/fourth gear synchronizer. 1. Install the gear wheel. 2. Install the synchronizer. 3. Install the circlip. 3 2 1 ELJ1601682 7. Install the fifth gear wheel. 1. Install the needle roller bearing. 2. Install the synchronizer ring.

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-39 308-03A-39 Manual Transmission - MT75 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES 3. Install the gear wheel. 3 2 1 ELJ1601680 8. Install the output shaft locating bearing, synchronizer ring and the input shaft. ELE0010467

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-40 308-03A-40 Manual Transmission - MT75 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Countershaft Special Tool(s) Remover, Bearing (Main Tool) 205-295 (15-050A) 15050A Collet for 205-295 308-146 (16-050) 16050 Disassembly 1. NOTE: Insert the special tool in the annular groove provided in the ring. Using the special tools, pull the bearing rings off the countershaft. 205-295 308-146 ELE0011325 Assembly 1. Install the bearing rings. ‡ Heat the bearing rings to approximately 100°C and slide on. J1601690

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-41 308-03A-41 Manual Transmission - MT75 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Reverse Idler Gear Disassembly 1. Disassemble the reverse gear idler shaft. 1. Drive out the roll pin. 2. Remove the bearing housing. 3. Remove the reverse idler gear. 4. Remove the needle roller bearing. 3 4 2 1 J1601191 Assembly 1. NOTE: Do not install the bearing housing twisted. The threaded holes must line up with one another. Assemble the reverse gear idler shaft. 1. Install the needle roller bearing. 2. Install the reverse idler gear. 3. Install the bearing housing. 4. Drive in the roll pin. 2 1 3 4 ELJ1601691

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-42 308-03A-42 Manual Transmission - MT75 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Synchronizers Materials Name Specification Manual transmission WSD-M2C200-C fluid Disassembly 1. CAUTIONS: Take care when pulling the selector ring off the synchronizer hub. The detent balls are spring-loaded. Mark the synchronizers to the synchronizer hubs in relation to the selector rings. Disassemble the synchronizer. 1. Selector ring. 2. Synchronizer hub. 3. Compression spring. 4. Blocker bar. 5. Detent ball. 1 3 2 4 5 V1601204 Assembly 1. NOTE: Carefully clean and check all sliding parts and lubricate them with Manuel transmission fluid before assembly. Assemble the inner synchronizer. 1. Synchronizer inner ring. 2. Blocker bars. 3. Compression springs. 1 2 2 3 3 ELE0012942 2. Assemble the outer synchronizer. 1. Synchronizer outer ring. 2. Detent balls. 1 2 2 ELE0012943

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-43 308-03A-43 Manual Transmission - MT75 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Gearshift Control Shaft Disassembly 1. Disassemble the gearshift control shaft. 1. Remove the roll pin. 2. Remove the shift finger. 3. Remove the selector fork. 1 2 3 ELE0010465 2. Disassemble the gearshift control shaft (continued) 1. Remove the locking sleeve. 2. Remove the roll pin and the selector finger. 1 2 ELE0010464 Assembly 1. NOTE: Make sure that the roll pins do not protrude. To assemble, reverse the disassembly procedure.

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-44 308-03A-44 Manual Transmission - MT75 ASSEMBLY Transmission Special Tool(s) Installer, Wear Sleeve Stub Axle 204-276 (14-055) 204276 Adapter for 205-066 205-066-04 (15-068) 15068 Flange Holding Wrench, Universal 205-072 (15-030A) 15030A Installer, Differential Bearing Cone 205-074 (15-035) 15035 Adapter for 205-074 205-074-01 (15-064) 15064 Installer, Rear Hub Oil Seal 205-075 (15-036) 15036 Special Tool(s) Aligner, Clutch Plate 303-173 (21-103A) 21103A Angle Gauge, Bolt Tightening 303-174 (21-540) 21540 Mounting Stand 303-435 (21-187) 21187 Socket, Guide Sleeve 308-109 (16-040A) PZ16040A Remover/Installer, Front Housing 308-110 (16-041) 16041 Threaded Spindle 308-111 (16-042A-01) 16042A01

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-45 308-03A-45 Manual Transmission - MT75 ASSEMBLY Special Tool(s) Adapter for 308-111 308-111-01 (16-042A) 16042A Installer, Input Shaft Seal 308-113 (16-044) 16044 Mounting Bracket for 303-435 308-114 (16-045) 16045 Mounting Brackets for 308-114 308-114-01 (16-045-01) 30811401 General Equipment 17 mm socket Materials Name Specification Manual transmission WSD-M2C200-C fluid Sealant WSS-M2G348-A10 Sealant ESK-M4G242-A Sealant - Loctite 518 WSK-M2G348-A5 Grease ESD-M2C220-A Assembly All vehicles 1. NOTE: Lubricate all moving parts with manual transmission fluid during assembly. NOTE: Clean and check all parts for wear and damage. Install new parts as necessary. NOTE: When installing a new transmission rear housing, install the locating studs with a 24 ± 0.5 mm protrusion. Using the special tools, install the output shaft bearing. 205-074-01 ELE0012604 2. Using the special tools, install the output shaft bearing. 205-066-04 205-074 ELE0012605 3. Install the output shaft bearing retaining bolts. 24Nm ELD1601667

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-46 308-03A-46 Manual Transmission - MT75 ASSEMBLY 4. Using the special tool, install the main selector shaft bearing. 303-173 D1601169 5. Using the special tool, install the countershaft rear bearing. 205-075 TIE0012613 6. Coat the lip of the main selector shaft oil seal with grease. 7. Using a 17 mm socket, install the main selector shaft oil seal. TIE0012606 8. NOTE: Install new selector gate retaining bolts. Install the selector gate. 10Nm ELE0012615 9. NOTE: Install a new input shaft bearing snap ring. Using the special tools, install the input shaft bearing. ‡ Install the snap ring in the annular groove of the bearing. 205-075 205-074-01 E0012611 10. Using the special tool, install the countershaft front bearing. 205-075 TIE0012614

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-47 308-03A-47 Manual Transmission - MT75 ASSEMBLY 11. Using the special tool, install the main selector shaft bearing. 303-173 ELE0012902 12. Assemble the countershaft to the output shaft and secure it with a cable tie. ELD1601677 13. NOTE: The first and second gear selector fork must engage in the middle of the first and second gear synchronizer unit. Assemble the main selector shaft to the countershaft and output shaft assembly. ELD1601676 14. NOTE: Make sure that the flat end of the reverse gear idler shaft is facing upwards. Assemble the reverse gear idler to the countershaft and output shaft assembly and secure it with cable ties. ELD1601679 15. NOTE: Make sure that the outtrigger of the selector fork is facing upwards. Attach the fifth and reverse gear selector fork to the lower synchronizer unit. ELD1601678 16. NOTE: During installation, guide the main selector shaft into the bearing and selector gate correctly. NOTE: Make sure that there is no touch condition between the countershaft and the synchronizer ring. NOTE: Make sure that the inside splines of the sensor ring are facing to the output shaft flange. Using the special tools, install the countershaft and output shaft assembly. 1. Install the vehicle speed sensor (VSS) ring.

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-48 308-03A-48 Manual Transmission - MT75 ASSEMBLY 2. Use the special tools to guide the countershaft into the rear bearing. 1 308-111-01 2 2 308-111 TIE0012607 17. Remove the VSS ring. 18. Install the magnetic disc. ELE0019847 19. NOTE: Do not fully tighten the reverse gear idler shaft rear retaining bolt at this stage. Install the reverse gear idler shaft rear retaining bolt. ELE0019846 20. Remove the cable ties from the countershaft and output shaft assembly. 21. NOTE: Make sure that the chamfered end of the selector shaft is facing upwards. Install the third and fourth gear selector fork and the auxiliary selector shaft. ELD1601661 22. CAUTION: Install the transmission front housing within 15 minutes of applying the sealant. Apply sealantto the mating surface of the transmission rear housing. ELE0012944

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-49 308-03A-49 Manual Transmission - MT75 ASSEMBLY 23. CAUTION: Install the transmission front housing carefully. Failure to follow this instruction may result in damage to the fourth gear synchronizer ring. Assemble the transmission front housing to the transmission rear housing. ELE0012903 24. NOTE: During installation, guide the countershaft carefully into the bearing. Using the special tool, install the transmission front housing. 308-110 ELE0013035 25. NOTE: Install a new input shaft circlip. Install the input shaft circlip. ELE0012904 26. Install the transmission housing retaining bolts. 24Nm ELE0012591 27. CAUTION: Check the reversing lamp switch gasket. If the gasket is loose or damaged, discard the reversing lamp switch. NOTE: Install new reversing lamp switch retaining bolts. Install the reversing lamp switch. 12Nm ELE0012905 28. Install the reverse gear idler shaft front retaining bolt ‡ Tighten the reverse gear idler shaft retaining bolts. 32Nm TIE0020642

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-50 308-03A-50 Manual Transmission - MT75 ASSEMBLY 29. Install the selector shaft locking plate bolt. 14Nm ELE0019849 30. Apply sealant to the selector interlock mechanism retaining plug. 31. Install the selector interlock mechanism. 24Nm ELE0012906 32. NOTE: Make sure that the inside splines of the sensor ring are facing the output shaft flange. Install the VSS ring. ELE0012581 33. Coat the lip of the output shaft oil seal with grease. 34. Using the special tool, install the output shaft oil seal. ‡ Install the splash shield. 204-276 TIE0012609 35. Using the special tools, install the output shaft flange. ‡ Hold the spindle with a drift. 308-11-01 308-111 TIE0012610 36. NOTE: Install a new output shaft flange retaining nut. Coat the threads and the mating surface of the output shaft retaining nut with sealant. 37. Using the special tool, install the output shaft flange retaining nut. 200Nm 205-072 ELE0012907

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-51 308-03A-51 Manual Transmission - MT75 ASSEMBLY 38. Using the special tool, install the input shaft guide sleeve oil seal. 308-113 ELE0012612 39. Assemble the input shaft guide sleeve. 1. Install the thrust washer. 2. Install the O-ring seal. 1 2 TIE0023796 40. Coat the threads of the input shaft guide sleeve and the O-ring seal with grease 41. Using the special tool, install the input shaft guide sleeve. 250Nm 308-109 ELE0012594 42. Coat the threads of the countershaft bearing retainer and the O-ring seal with grease. 43. NOTE: Install a new countershaft bearing retainer O-ring seal. Install the countershaft bearing retainer. 24Nm ELE0012909 44. Using the special tool, loosen the bearing retainer by 80 degrees. 303-174 ELE0012910 45. NOTE: Rotate the transmission housing downwards at least 45 degrees. Adjust the countershaft. ‡ Using a suitable brass drift and a soft faced hammer, strike two blows on each of the bosses. This will seat the countershaft front bearing against the bearing retainer. ELE0012911

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-52 308-03A-52 Manual Transmission - MT75 ASSEMBLY 46. CAUTION: The indicated torque must be achieved. Using the special tool, tighten the bearing retainer 20 degrees. ‡ If the indicated torque is not achieved, repeat the previous two steps. 6 N m 303-174 ELE0012912 47. NOTE: Install a new countershaft bearing retainer locking plate bolt. Install the countershaft bearing retainer locking plate. 25Nm 48. Install the clutch release bearing and the clutch release lever. ELE0012577 49. Remove the transmission from the mounting stand. 303-435 308 -114-01 308-114 ELE0019850 50. Install the vehicle speed sensor. ‡ Coat the VSS O-ring seal with grease 8 Nm E92149 51. Install the drain plug. 35Nm ELE0012915

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-53 308-03A-53 Manual Transmission - MT75 ASSEMBLY Vehicles with tachograph 52. Install the tachograph sensor. ELE0019852 2 1 12 Nm E91972 All vehicles 53. Install the external gearshift control assembly. ‡ Make sure that one of the flat sides of the output shaft flange is upper most. 1. Install the bolt and nut. NOTE: Only tighten the bolts finger tight at this stage. 2. Install the bolts. 2

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-54 308-03A-54 Manual Transmission - MT75 ASSEMBLY 54. Shift the transmission into 4th gear. E91971 55. Move the external gearshift control assembly, to achive the dimension shown. mm mm E91973 56. Make sure that the spring touches the pin on both sides. E91970 57. Tighten the external gearshift control assembly bolts in the sequence shown. 3 25 Nm 25 Nm 1 2 E73391 58. Make sure that the spring touches the pin on both sides in 4th gear, neutral and 3rd gear position. If not, loosen the external gearshift control assembly bolts and repeat the previous four steps. E91970 59. Install the external gearshift control cover. E91969 60. Fill the transmission with manual transmission fluid . For additional information, refer to: Transmission Draining and Filling (308-03

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-55 308-03A-55 Manual Transmission - MT75 ASSEMBLY Manual Transmission/Transaxle - Vehicles With: MT-75, General Procedures).

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-56 308-03A-56 Manual Transmission - MT75 INSTALLATION Transmission – 2WD Installation General Equipment Transmission Jack 1. Check the pilot bearing for damage. If damaged, install a new pilot bearing. Refer to: Pilot Bearing - 2.5L Duratec-HE (122kW/165PS) - MI4 (308-01 Clutch - Vehicles With: 5-Speed Manual Transmission - MT75, Removal and Installation). 2. NOTE: Do not apply grease to a newly installed pilot bearing. Apply approximately one gram of grease to the pilot bearing. 3. Apply a thin film of grease to the input shaft guide sleeve. 4. Shift the transmission into third gear. All vehicles 5. General Equipment: Transmission Jack Torque: 48 Nm x2 x2 x4 x4 E134602 6. Torque: 48 Nm x3 x3 E132702 7. 1. Torque: 25 Nm 2. Torque: 40 Nm 2 1 x2 x2 E134601

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-57 308-03A-57 Manual Transmission - MT75 INSTALLATION 8. E134600 x4 x4 E134599 9. Torque: 90 Nm

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-58 308-03A-58 Manual Transmission - MT75 INSTALLATION 10.Lower the transmission jack. E128845 11. Torque: 55 Nm x2 E134598 12.Torque: 25 Nm E132699 Vehicles with 2.5L engine 13.Torque: 50 Nm E132504 14. x2 E136413 15.Torque: 1 1 Nm E132697

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-59 308-03A-59 Manual Transmission - MT75 INSTALLATION All vehicles 16.NOTE: Uncap the fluid line. E132696 17.Torque: 35 Nm x2 x2 E132695 18.Torque: 35 Nm x2 x2 E132694 19.Refer to: Driveshaft - 2WD (205-01 Driveshaft, Removal and Installation). 20.Refer to: Jacking (100-02 Jacking and Lifting, Description and Operation). Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation). 21.Refer to: Catalytic Converter (309-00 Exhaust System - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 22. E132693 23.Refer to: Floor Console - Single Cab (501-12 Instrument Panel and Console, Removal and Installation). Refer to: Floor Console - Double Cab (501-12 Instrument Panel and Console, Removal and Installation). 24.Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-60 308-03A-60 Manual Transmission - MT75 INSTALLATION Transmission – 4WD Installation 1. Check the pilot bearing for damage. If damaged, install a new pilot bearing. Refer to: Pilot Bearing - 2.5L Duratec-HE (122kW/165PS) - MI4 (308-01 Clutch - Vehicles With: 5-Speed Manual Transmission - MT75, Removal and Installation). 2. NOTE: Do not apply grease to a newly installed pilot bearing. Apply approximately one gram of grease to the pilot bearing. 3. Apply a thin film of grease to the input shaft guide sleeve. 4. Shift the transmission into third gear. All vehicles 5. Torque: 25 Nm x2 x2 E132705 6. x4 E132704 7. E132703

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-61 308-03A-61 Manual Transmission - MT75 INSTALLATION 8. Torque: 48 Nm x2 x4 E132701 x4 E132455 11. Torque: 90 Nm x4 E132700 9. Torque: 48 Nm x3 E132702 10.Torque: 90 Nm

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-62 308-03A-62 Manual Transmission - MT75 INSTALLATION 12.Lower the transmission jack. E128845 13.Torque: 48 Nm x4 E129203 14.Torque: 25 Nm E132699 Vehicles with 2.5L engine 15.Torque: 50 Nm E132504 16. x2 E136413 17.Torque: 1 1 Nm E132697

Manual Transmission/Transaxle – Vehicles With: 5-Speed 308-03A-63 308-03A-63 Manual Transmission - MT75 INSTALLATION All vehicles 18.NOTE: Uncap the fluid line. E132696 19.Torque: 35 Nm x2 x2 E132695 20.Torque: 35 Nm x2 x2 E132694 21.Refer to: Driveshaft - 4WD (205-01 Driveshaft, Removal and Installation). Refer to: Front Driveshaft - 4WD (205-01 Driveshaft, Removal and Installation). 22.Refer to: Jacking (100-02 Jacking and Lifting, Description and Operation). Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation). 23.Refer to: Catalytic Converter (309-00 Exhaust System - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation). 24. E132693 25.Refer to: Floor Console - Single Cab (501-12 Instrument Panel and Console, Removal and Installation). Refer to: Floor Console - Double Cab (501-12 Instrument Panel and Console, Removal and Installation). 26.Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).