Transmision

8/9/2017 Direct-Hit -- Bsqueda
DIAGNOSIS AND TESTING: AUTOMA...

DISASSEMBLY AND ASSEMBLY: TRANSAXLE (AUTOMATIC SHIFTING MANUAL TRANSMISSION/TRANSAXLE)
307-11 Automatic Shifting Manual Transmission/Transaxle 2012 Fiesta
DISASSEMBLY AND ASSEMBLY Procedure revision date: 12/17/2013
Transaxle
Special Tool(s)
Slide Hammer
100-001
Holding Fixture
307-580
Installer, Input Guide and Seal

307-672 (includes 307-672/1 and 307-672/2)
Fixture, Clutch Remover/Installer

307-675 (includes 307-675/1, 307-675/2, 307-675/3
and 307-675/4)
Table, Assembly (DPS6)

307-680 (includes 307-680/1, 307-680/2, 307-680/3,
307-680/4 and 307-680/5)
Remover, Input Shaft Oil Seal

308-375
Material
Item Specification
DPS6 Grease WSS-
http://dh.identifix.com/SearchFixes/Index?ROID=174303470&VID=2377673&VSM=1&LocationId=2#KW=P287B&SOption=1&VETId=8&STMode=1&Paging=&SMode=2&position=0 1/53
9U7Z-19A506-BA M1C270-A
Motorcraft Gasket Maker WSK-
TA-16 M2G348-A5
Motorcraft High Temperature Nickel Anti-Seize -
Lubricant
XL-2
Motorcraft Dual Clutch Transmission Fluid WSS-
XT-11-QDC M2C200-D2
Transmission Exploded View
Item Part Number Description

1 7B546 Clutch assembly (part of 7C601 kit)
2 W790187 Actuator lever bolts (4 required)
3 7515 Actuator lever 1 (part of 7C601 kit)
4 7N080 Actuator lever dowels (2 required)
5 7515 Actuator lever 2 (part of 7C601 kit)
6 7A508 Engagement bearing (part of 7C603 kit)
7 7A564 Guide tube
8 W790185 Guide tube bolts (3 required)
9 7L013 Drain plug
10 7048 Input shaft case seal
11 1177 Halfshaft seals (2 required)
12 7505 Clutch housing
13 4067 Differential shim (part of kit)
14 4220 Differential bearings (2 required)
15 7M037 Output shaft bearings (2 required)
16 7060 Output shaft assembly
17 W790208 Output shaft bearing retainer bolts (6 required)

18 7060 Output shaft assembly
19 7H150 Differential impulse ring
20 W790237 Differential ring gear bolts (10 required)
21 7D392 Differential ring gear
22 4026 Differential case
23 7L027 Magnet
24 7005 Transmission case
25 7C013 Fill plug
26 W790189 Transmission Control Module (TCM) bolt
27 W790209 Clutch housing-to-case bolts (21 required)
28 W790188 TCMbolt
29 7Z369 TCM
30 7B498 TCMO-ring seal
31 7118 Input shaft bearing
32 7D000 Oil spout
33 7017 Inner input shaft
34 7M037 Needle bearing
35 7M037 Needle bearing
36 7118 Bearing
37 7017 Hollow input shaft
38 7917 Input shaft snap ring
39 7064 Hollow input shaft snap ring
40 7052 Hollow input shaft seal
41 W790236 Bolts (3 required)
42 7049 Bearing retainer
43 7D000 Lube feed tubes (2 required)
44 7118 Input shaft bearing
45 7052 Manual control lever shaft seal
46 - Shift drum pin (2 required) (part of 7J047)

47 7J047 Shift drum (2 required)
48 7J048 Small clock gear (2 required)
49 7J048 Large clock gear (2 required)
50 6397 Clock gear pin (2 required)
51 6397 Clock gear pin (2 required)
52 7L013 Park plunger plug
53 7233 Park plunger
54 6397 Park pawl rod
55 7A248 Park pawl
56 7H296 Park pawl actuation shaft assembly
57 7A256 Manual control lever
58 W790198 Manual control lever bolt
59 7240 Shift fork rod
60 7230 2nd/6th gear shift fork
61 7B081 3rd gear shift fork linkage
62 7B081 2nd/6th gear shift fork linkage
63 7230 4th/reverse gear shift fork
65 7230 3rd gear shift fork
67 7230 1st/5th gear shift fork
69 W790186 Bolt
70 7M101 Input shaft speed sensor
71 7Z101 Input shaft speed sensor shim
72 7Z101 Input shaft speed sensor shim
73 7F293 Transmission Range (TR) sensor

76 7C604 Clutch motor (2 required)
77 7G276 Transmission wiring harness
78 7H103 Output Shaft Speed (OSS) sensor
79 7064 Clutch hub snap ring
Disassembly
1. NOTE:Take note of the transmission wiring harness clip locations for installation.
Remove the transmission wiring harness.
2. Remove the 4 Transmission Control Module (TCM) bolts.
3. Using a flat blade screwdriver, carefully pry the TCMfrom the transmission, at the location shown, and remove the TCM.
4. Remove and discard the TCMO-rings.
5. Remove the 2 Transmission Range (TR) sensor bolts and the TRsensor.
6. Remove the Output Shaft Speed (OSS) sensor bolt and OSSsensor.
7. Remove the input shaft speed sensor 1.

1. Remove the input shaft speed sensor 1 bolt.
3. Remove the input shaft speed sensor 1 shim.

1. Remove the input shaft speed sensor 2 bolt.

3. Remove the input shaft speed sensor 2 shim.
9. Install the special tools.
10. Stand the transmission on its back.
11. Remove the 4 clutch motor 1 bolts and remove clutch motor 1.
12. Remove the 4 clutch motor 2 bolts and remove clutch motor 2.
13. Remove and discard the clutch hub snap ring.
14. NOTE:Index mark the clutch hub and clutch for installation.
Remove the clutch hub.
16. Using the special tools, turn the center bolt of the special tool with a maximum of 5 Nm (44 lb-in) of torque to push the clutch
down to release the pressure from the hollow input shaft snap ring.
17. Remove and discard the hollow input shaft snap ring.
18. NOTE:Make sure the lifting legs are installed on the 3 clutch studs marked with the manufacturing mark as shown.
NOTE:Make sure the lifting leg with the angle is in the location shown.
Install the special tools.
20. Turn the center bolt of the special tool with approximately 5 Nm (44 lb-in) of torque until the clutch is free of the input shaft.
21. Using the special tools, remove the clutch as an assembly from the transmission.
22. Using the special tool, remove and discard the inner input shaft seal.
23. Remove the Z-washers from the engagement system bearing unit.
24. NOTE:The engagement system bearing unit should be removed easily.
Remove the engagement system bearing unit. Inspect for wear or damage. Replace as necessary.
25. NOTICE: Remove the spring retainer bolts by loosening them slightly in an alternating pattern or damage can occur
to the clutch actuator levers.
NOTE:The spring retainers and actuator levers are matched sets with corresponding serial numbers. If the spring retainers
and actuator levers are being reused, mark on each spring retainer and actuator lever for assembly.
Remove the 4 spring retainer bolts from the spring retainers and remove the spring retainers.
26. Install clutch actuator lever locks as shown if available.
27. Remove the 2 bolts from the clutch actuator lever 1.
28. Remove the 2 bolts from the clutch actuator lever 2.
29. NOTICE: Be sure to properly handle the actuator lever as shown or damage may occur.
Remove the clutch actuator lever 1.
Remove the clutch actuator lever 2.
31. Remove the guide tube bolts.
32. Remove the guide tube.
33. Using the special tools, remove and discard the input shaft case seal.
34. Remove and discard the input shaft snap ring.
35. Remove discard the manual control lever bolt and remove the manual control lever.
36. Remove the top 3 clutch housing-to-case bolts.
37. Remove the bottom 18 clutch housing-to-case bolts (13 shown).
38. Install the special tool.
39. NOTE:Install the special tools in the position shown.
Install the special tools and special tools bolts.

Tighten to 18 Nm (159 lb-in).
40. Turn the special tool bolt approximately 20 turns to separate the clutch housing from the transmission case.
41. Lift the clutch housing off the transmission case.
42. Remove and discard the clutch housing input shaft bearing retainer bolts and remove clutch housing input shaft bearing
retainer.
43. By lightly tapping, remove and discard the clutch housing input shaft bearing.
44. Remove the park plunger plug.
45. Remove the park plunger.
46. Remove the differential.
47. Remove the park pawl actuation shaft assembly.
48. Remove the park pawl rod and park pawl.
49. Remove the large clock gears and clock gear pins.
50. Remove the small clock gears and clock gear pins.
51. Remove the magnet.
52. Install the special tool on the transmission case and gear set assembly.
53. Turn the transmission case and gear set assembly over on the special tool.
54. Remove the special tool from the transmission case.
55. Remove and discard the 6 output shaft bearing retainer bolts.
56. Lift the transmission case off the gearset assemblies.
57. NOTE:This step only applies to transmissions built before April-2013.
Remove the oil spout.
58. Remove the 4 shift fork rods.
59. Remove the 2 shift drums.
60. Remove the shift forks and linkages.
62. Turn the gearset assembly over on its side.
63. Remove the special tool.
64. Remove output shaft 1 assembly by removing the special tool.
65. Remove the input shaft assembly by removing the special tool.
66. Remove the special tool from output shaft 2 assembly.
67. Remove the hollow input shaft from the solid input shaft.
Assembly
1. Install the hollow input shaft onto the inner input shaft.
2. NOTE:If the clearance is less than the minimum measurement stated in the specifications section, install a new shift fork.
Using a suitable feeler gauge, measure the clearance between the shift fork and synchronizer hub sleeve in various places
around the circumference.
3. NOTE:Apply pressure on the synchronizer ring while taking the measurements.
NOTE:If the clearance is less than the minimum measurement stated in the specifications section, install a new output shaft
assembly.
Using a suitable feeler gauge, measure the clearance between the synchronizer ring and gear in various places around the
circumference.
4. NOTE:Make sure the synchronizers are in the neutral position.
Install output shaft 2 assembly on the special tool.
5. Install the input shaft assembly on the special tool.
6. NOTE:Make sure the synchronizers are in the neutral position.
Install output shaft 1 assembly on the special tool.
8. Turn the gearset assembly over onto the special tool.
10. Install the 4th/reverse gear shift fork.
11. Install the 2nd/6th gear shift fork and linkage.
12. NOTE:Make sure shift drum 1 is in the neutral position as shown.
Install shift drum 1.
13. NOTE:Make sure shift drum 2 is in the neutral position as shown.
Install the 3rd gear linkage and shift drum 2.
14. Install the 1st/5th gear shift fork.
15. Install the 3rd gear shift fork.
16. Install the 4 shift fork rods.

1. Install the small shift fork rods.
2. Install the large shift fork rods.
17. NOTE:This step only applies to transmissions built before April-2013.
Install the oil spout.
18. NOTE:Make sure the output shaft bearing retainer brackets are positioned as shown.
Install the special tools on the output shafts assemblies.
19. Install the transmission case onto the gearset assemblies.
20. Install the 6 new output shaft bearing retainer bolts. Tighten in 2 stages.
Stage 1: tighten to 10 Nm (89 lb-in).
Stage 2: tighten to 32 Nm (24 lb-ft).
21. Install the special tool on the transmission case.
22. Turn the transmissioncase and gearset assembly over onto the special tool.
24. Install the magnet.

25. Install the small clock gears and clock gear pins.
26. Install the large clock gears and clock gear pins.
27. Install the park pawl and park pawl rod.
28. NOTE:Make sure the pin is installed as shown.
Install the park pawl actuation shaft assembly.
29. NOTE:If the differential bearings, differential, clutch housing and/or transmission case are replaced refer to Differential Shim
Selectionin this section.
Install the differential.
30. NOTICE: Make sure the transmission case and the clutch housing are clean and no old sealant is present or
transmission fluid leaks can occur and cause transmission damage.
NOTICE: Make sure the park plunger and park plunger plug were removed from the the clutch housing or damage to
the park pawl actuation shaft assembly (rooster comb) will occur.
Apply a 1 mm (0.039 in) bead of Gasket Maker around the inside of the bolt holes on the case side and completely around
each dowel.
31. Using the special tools, install the new clutch housing input shaft bearing.
32. Install the clutch housing input shaft bearing retainer and the new clutch housing input shaft bearing retainer bolts.
33. NOTICE: Do not overheat the bearing or damage to the bearing may occur.
Using a 1500W heat gun, or equivalent, heat the input shaft bearing in the clutch housing for approximately 5 minutes.
34. NOTICE: Be sure that the park pawl detent is NOT already installed when installing the clutch housing on the
transmission case. If the transmission was disassembled for a repair that did not require complete transmission
disassembly, the park pawl detent must be removed before installing the clutch housing or damage to the park pawl
actuator shaft will occur.
Install the clutch housing onto the transmission case.
35. Using the special tool and a hammer, tap the clutch housing down onto the transmission case.
36. Install the 18 bottom clutch housing-to-case bolts (13 shown).

Tighten to 27 Nm (20 lb-ft).
37. Install the 3 top clutch housing-to-case bolts.

38. Install the park plunger.
39. Install the park plunger plug.

40. Install the manual control lever and the new manual control lever bolt.
41. Install a new input shaft snap ring.
42. Using the special tools, install a new input shaft case seal.
43. Using the locating flange on the guide tube, install the guide tube.
44. NOTE:The guide tube bolts must not project beyond the mounting surface of the clutch engagement levers.
Install the 3 guide tube bolts.

45. Inspect the guide tube for wear or damage. Replace as necessary.
46. NOTE:One clutch actuator lever bushing shown, one per clutch actuator lever.
Install the clutch actuator lever bushings.
Install the clutch actuator lever 2.
48. Install clutch motor 2 without the bolts to aide in the alignment of the clutch actuator lever.
49. Install the 2 clutch actuator lever 2 bolts.

Install the clutch actuator lever 1.
51. Install clutch motor 1 without the bolts to aide in the alignment of the clutch actuator lever.
52. Install the 2 clutch actuator lever 1 bolts.

53. NOTICE: Tighten the spring retainer bolts by tightening them slightly in an alternating pattern or damage can occur
to the clutch actuator levers.
NOTE:Make sure the spring retainer contour aligns with the actuator lever contour as shown.
NOTE:Make sure the serial number on the spring retainer matches the serial number on the actuator lever. If reusing the
spring retainers and actuator levers use the marks made during removal for assembly.
Install the spring retainers and spring retainer bolts.

54. Remove the clutch actuator lever locks if installed.
55. NOTICE: Do not apply grease or other lubricants to the clutch actuator lever fingers, the engagement system
bearing, or the Z-washers or clutch contamination can occur.
NOTE:The engagement system bearing unit should be installed easily.
Install the engagement system bearing unit.
56. NOTICE: Do not tilt transmission after the Z-washers are installed, they may come off center and damage can occur.
Install the Z-washers onto the engagement system bearing unit and center them correctly.
57. If installing a new clutch go to step 70.
58. NOTE:Make sure the special tool washer is also installed.
Install the special tool in a vise.
59. Place the clutch on the special tool and align one clutch stud with the slotted hole on the special tool.
60. Install the special tool loosely on the clutch.
61. Install the special tool on the clutch making sure the legs are inserted in the slots.
62. Turn the special tool clockwise to the stops and hold.
63. NOTICE: Failure to rotate the self-adjuster to the stops before compressing the clutch, causes damage to the clutch.
Tighten the special tool until the 3 clutch 1 locks can be locked in place by hand.
64. Install the special tool loosely on the clutch.
65. Using the special tool, move the clutch self-adjuster counterclockwise to the stop and hold.
66. NOTICE: Make sure the clutch self-adjuster is held to the stops before compressing the clutch or damage will occur
to the clutch.
NOTE:An audible click can be heard when the clutch locks lock.
While holding the clutch self-adjuster to the stops, use the special tool and compress the clutch to the stops on the clutch.
The locks on clutch 2 lock at this time.
67. Remove the special tools.
68. NOTE:The minimum number of engaged clutch locks is 6. Make sure the 6 locked clutch fingers align with the clutch studs as
shown. If not, reset the clutch 2 locks as necessary.
Visually check the locks to make sure they have locked. 4 locks shown, 12 total.
69. If installing a used clutch, verify the clutch is not worn or damaged. Perform the next 2 steps to check for clutch wear.
70. Check clutch 1 for wear by measuring the distance between the adjuster ring 1 long hole and lever 1 spring. Replace the
clutch assembly if the measurement is 26 mm (1.023 in) or less.
71. Check clutch 2 for wear by measuring the distance between adjuster ring 2 and the cover. Replace the clutch assembly if the
measurement is 15 mm (0.59 in) or less.
72. Using the special tools, install the new inner input shaft seal.
73. Apply a small amount of transmission fluid on the input shaft bearing surface.
74. Apply a small amount of DPS6 Grease on both input shaft splines.
75. Verify the Z-washers are installed correctly.
76. NOTICE: Verify the clutch locks are locked prior to installation or the transmission may not operate correctly and
damage can occur. If the clutch locks are not locked go to step 56 within this procedure.
NOTE:Make sure the angled lifting leg is installed in the location shown.
Using the special tools, install the clutch in the transmission.
77. Remove all the special tools.
78. Install the special tools onto the transmission case.
79. NOTICE: Do not overtighten the special tool or damage can occur.
Using the special tools, push the clutch down with approximately 5 Nm (44 lb-in) of torque until seated on the input shaft
bearing and the snap ring groove is visible.
80. NOTE:Make sure the hollow input shaft snap ring is fully seated.
Install the new hollow input shaft snap ring.
81. NOTE:Align the index marks on the clutch hub and clutch.
Install the clutch hub.
82. Install the new clutch hub snap ring in the position shown.
83. NOTICE: Do not turn the special tool more than 12 turns or damage to the clutch actuator engagement lever can
occur.
Using the special tool, release the clutch 1 locks by slowly turning the special tool counterclockwise. An audible click will be
heard when the clutch 1 lock is released. Repeat step to release clutch 2 locks.
84. Apply High Temperature Nickel Anti-Seize Lubricant to both clutch motor surfaces where indicated.
85. Apply High Temperature Nickel Anti-Seize Lubricant to the clutch actuator lever splines as shown.
86. Install the clutch motor 2 and the 4 clutch motor 2 bolts.
87. Install the clutch motor 1 and the 4 clutch motor 1 bolts.
88. NOTICE: Be sure to use the 3.2 mm (0.125 in) input shaft speed sensor 2 shim or damage can occur to the
transmission.
NOTE:Install a new O-ring if installing the existing input shaft speed sensor 2.
NOTE:Use a small amount of transmission fluid on the input shaft speed sensor 2 O-ring for installation.
Install the input shaft speed sensor 2.

1. Install the input shaft speed sensor 2 shim.
2. Install the input shaft speed sensor 2.
3. Install the input shaft speed sensor 2 bolt.
89. NOTICE: Be sure to use the 3.5 mm (0.137 in) input shaft speed sensor 1 shim on input shaft speed sensor 1 or
damage can occur to the transmission.
NOTE:Install a new O-ring if installing the existing input shaft speed sensor 1.
NOTE:Use a small amount of transmission fluid on the input shaft speed sensor 1 O-ring for installation.
Install the input shaft speed sensor 1.

1. Install the input shaft speed sensor 1 shim.
2. Install the input shaft speed sensor 1.
3. Install the input shaft speed sensor 1 bolt.
90. NOTE:If installing the old OSSsensor, install a new O-ring.

Install the OSSsensor and the OSSsensor bolt.

91. Install the TRsensor and the 2 TRsensor bolts.

92. Carefully inspect the TCMand the transmission bore for debris or damage. Clean and/or repair as needed.
93. NOTE:Use a small amount of transmission fluid on the new O-rings prior to installation.
Make sure to install new O-rings.
94. NOTICE: Do not force the TCMonto the transmission or damage may occur.
NOTICE: Make sure the TCMsits flush on the transmission, or damage can occur.
Install the TCM. Apply light pressure to seat the O-rings. If the TCMdoes not push in place with light pressure, remove the
TCMand slightly turn the TCMgears and retry installing the TCM.
95. Install the 4 TCMbolts.

96. Install the wiring harness.
Copyright 2014 Ford Motor Company
This publication contains material that is reproduced and distributed under a license from Ford Motor Company. No further
reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor
Company.
Copyright 2007 - 2014 Service Repair Solutions, Inc.

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8/9/2017 Direct-Hit -- Bsqueda

DIAGNOSIS AND TESTING: AUTOMA...

Installer, Input Guide and Seal

Fixture, Clutch Remover/Installer

Table, Assembly (DPS6)

Remover, Input Shaft Oil Seal

Transmission Exploded View

Item Part Number Description

17 W790208 Output shaft bearing retainer bolts (6 required)

46 - Shift drum pin (2 required) (part of 7J047)

75 W790175 Bolts (8 required)

Remove the transmission wiring harness.

2. Remove the 4 Transmission Control Module (TCM) bolts.

4. Remove and discard the TCMO-rings.

7. Remove the input shaft speed sensor 1.

8. Remove the input shaft speed sensor 2.

2. Remove the input shaft speed sensor 2.

9. Install the special tools.

10. Stand the transmission on its back.

13. Remove and discard the clutch hub snap ring.

Remove the clutch hub.

15. Install the special tools.

Install the special tools.

19. Install the special tools.

24. NOTE:The engagement system bearing unit should be removed easily.

26. Install clutch actuator lever locks as shown if available.

27. Remove the 2 bolts from the clutch actuator lever 1.

28. Remove the 2 bolts from the clutch actuator lever 2.

Remove the clutch actuator lever 1.

Remove the clutch actuator lever 2.

31. Remove the guide tube bolts.

32. Remove the guide tube.

34. Remove and discard the input shaft snap ring.

36. Remove the top 3 clutch housing-to-case bolts.

37. Remove the bottom 18 clutch housing-to-case bolts (13 shown).

38. Install the special tool.

39. NOTE:Install the special tools in the position shown.

Install the special tools and special tools bolts.

41. Lift the clutch housing off the transmission case.

44. Remove the park plunger plug.

45. Remove the park plunger.

46. Remove the differential.

47. Remove the park pawl actuation shaft assembly.

48. Remove the park pawl rod and park pawl.

51. Remove the magnet.

54. Remove the special tool from the transmission case.

56. Lift the transmission case off the gearset assemblies.

57. NOTE:This step only applies to transmissions built before April-2013.

Remove the oil spout.

58. Remove the 4 shift fork rods.

59. Remove the 2 shift drums.

60. Remove the shift forks and linkages.

61. Install the special tool.

62. Turn the gearset assembly over on its side.

63. Remove the special tool.

64. Remove output shaft 1 assembly by removing the special tool.

66. Remove the special tool from output shaft 2 assembly.

3. NOTE:Apply pressure on the synchronizer ring while taking the measurements.

4. NOTE:Make sure the synchronizers are in the neutral position.

Install output shaft 2 assembly on the special tool.

5. Install the input shaft assembly on the special tool.

6. NOTE:Make sure the synchronizers are in the neutral position.

Install output shaft 1 assembly on the special tool.