Transmission

1. 1. NOTE: In order to avoid incorrect readings, do not oil the taper roller bearings.

      General Equipment : Hot Air Gun
   3. Special Tool(s) : 205-075 Installer, Rear Wheel Hub Seal

1. Special Tool(s) : 205-075 Installer, Rear Wheel Hub Seal

1. 1. General Equipment : Hot Air Gun
   3. Special Tool(s) : 205-075 Installer, Rear Wheel Hub Seal

1. Special Tool(s) : 205-075 Installer, Rear Wheel Hub Seal

1. NOTICE: The surfaces must be thoroughly cleaned.

   Tighten the bolts in a crisscross sequence.
   Torque : 18 Nm

1. NOTE:

   Clean the end face of the differential assembly and mark it at one place.
   Install Special Service Tool : 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge

1. Repeat this and the following three steps three times and determine the average values.
   Special Tool(s) : 303-350 (T89P-6565-A) Compressor, Valve Spring

1. • Turn the differential until the measuring pin is on the marked spot.
     
   • Pre-load the dial gauge to 1 mm and zero it.
     Install Special Service Tool : 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge

1. 1. Special Tool(s) : 303-350 (T89P-6565-A) Compressor, Valve Spring
   2. Turn the differential until the measuring pin is on the marked spot.
      
   3. Measure the differential end float: Make a note of the measurement; Example: 0.265 mm + 0.255 mm + 0.260 mm, divided by 3 = 0.260 mm.
      

1. • Determine the thickness of the differential adjusting shim:
     
   • Determined differential end float is X mm.
     
   • Differential bearing pre-load 0.14 mm.
     
   • Required adjusting shim thickness: X mm + 0.14 mm = X mm.
     
   • Determined adjusting shim thickness.
     
   • If the determined adjusting shim thickness is unequal, then use the next closest thickness of adjusting shim.
     

1. Remove Special Service Tool : 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge

1. General Equipment : Punch

1. Special Tool(s) : 308-849 Installer Shift Shaft Bushing

1. 1. General Equipment : Hot Air Gun
   3. Determined adjusting shim.
      

1. Special Tool(s) : 308-880 Installer, Driveshaft Seal

1. Special Tool(s) : 205-075 Installer, Rear Wheel Hub Seal , 205-115 Installer, Drive Pinion Seal

1. Special Tool(s) : 308-849 Installer Shift Shaft Bushing
   Material : Motorcraft® Dual Clutch Transmission Fluid / XT-11-QDC (WSS-M2C200-D2)

1. Special Tool(s) : 308-849 Installer Shift Shaft Bushing

1. Material : Silicone Brake Caliper Grease and Dielectric Compound / XG-3-A (ESE-M1C171-A)

1. Material : Silicone Brake Caliper Grease and Dielectric Compound / XG-3-A (ESE-M1C171-A)

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

1. 2. NOTICE: Take extra care not to damage the bearing.

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

1. NOTICE: Take extra care not to damage the bearings.

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

   3. NOTICE: Take extra care when handling the component.

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

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

1. 1. Install Special Service Tool : 307-680 Table, Assembly (DPS6)
   2. Material : Gasket Maker / TA-16 (WSK-M2G348-A5)

1. 1. NOTICE: Make sure that new bolts are installed.

      Torque :
        Stage 1:  18 Nm
        Stage 2:  90°
   2. Remove Special Service Tool : 307-680 Table, Assembly (DPS6)

1. 1. NOTICE: Make sure that new bolts are installed.

      Torque :
        Stage 1:  18 Nm
        Stage 2:  90°

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

      Material : Gasket Maker / TA-16 (WSK-M2G348-A5)
   3. Torque : 20 Nm
   5. Special Tool(s) : 308-880 Installer, Driveshaft Seal

1. NOTE: Re-use the O-ring seal unless it is damaged.

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

1. 1. NOTE: Make sure that the selector lever is in the neutral (N) position.

   2. NOTICE: Make sure that no components catch.

   3. Torque : 24 Nm

1. Torque : 24 Nm

1. 1. NOTICE: Use adhesive tape to cover the input shaft splines to prevent damage to the input shaft seal.

      General Equipment : Adhesive Tape
   3. Special Tool(s) : 308-847 Installer, Inputshaft Seal

1. 1. Torque :
        Stage 1:  18 Nm
        Stage 2:  90°
   2. Torque : 10 Nm
   4. Special Tool(s) : 308-880 Installer, Driveshaft Seal
   5. Remove Special Service Tool : 307-003 (T57L-500-B) Holding Fixture, Transmission

1. If equipped.
   Torque : 48 Nm

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