Ford Focus Service Manual: Transaxle - Disassembly (Manual Transaxle/Transmission — MTX75)

	Heat Gun 107-R0300 or equivalent
	Holding Fixture, Transmission 307-003 (T57L-500-B)
	Remover, Pilot Bearing 308-001 (T38L-101-B)

Disassembly

1. Clean the transaxle exterior with solvent and dry with compressed air.

1. Clean all parts removed with solvent and dry with compressed air.

1. Remove and discard the clutch slave cylinder.

1. Install the Transmission Holding Fixture.

1. NOTE:

   Position the selector in the NEUTRAL position.

   Remove the 6 gearshift mechanism bolts and the gearshift mechanism.

1. Remove the Vehicle Speed Sensor (VSS) .

1. NOTE:

   Rotate the transaxle with the input shaft pointing upward.

   Remove the 16 transaxle housing bolts.

1. NOTICE: Take care not to damage the transaxle housing.

   Carefully pry the transaxle housing from the transaxle main case.

1. Remove the transaxle housing.

1. Remove the differential assembly.

1. Remove and clean the magnetic disc.

1. Remove the shift rails and the 1st and 2nd gear shift fork.

1. Remove the shift forks.
   1. Move the 5th and reverse gear selector fork to the side.
   1. Rotate the 3rd and 4th gear selector fork and remove, then remove the 5th and reverse gear selector fork.

1. Remove the 2 reverse idler gear bolts.

1. Lift out the input and the output shaft from transaxle housing together.

1. Remove the reverse idler gear retainer, then lift out the reverse idler gear.

1. Remove the following:
   1. Upper thrust washer
   1. Reverse idler gear
   1. Reverse idler gear bearing
   1. Lower thrust washer

1. Remove and discard the halfshaft oil seals.

1. Using a Heat Gun, heat the case bearing cup area. Using the Pilot Bearing Remover, remove the differential bearing race from the case (clutch side).

1. Using a Heat Gun, heat the case bearing cup area. Using the Pilot Bearing Remover, remove the output shaft bearing race (clutch side).

1. Using a Heat Gun, heat the case bearing cup area. Using the Pilot Bearing Remover, remove the input shaft bearing race (clutch side).

1. Remove the shims.

1. Using a Heat Gun, heat the case bearing area. Using the Pilot Bearing Remover, remove the input shaft bearing race from the case (transmission side).

1. Using a Heat Gun, heat the case bearing area. Using the Pilot Bearing Remover, remove the output shaft bearing race from the case (transmission side).

1. Using a Heat Gun, heat the case bearing area. Using the Pilot Bearing Remover, remove the differential bearing race from the case (transmission side).

1. NOTE:

   Only remove the reverse gear idler shaft if there is evidence of damage or leaks.

   Remove the 3 reverse gear idler shaft cover bolts and the reverse gear idler shaft cover.

1. NOTE:

   Only remove the reverse gear idler shaft if there is evidence of damage or leaks.

   Using a brass drift, remove the reverse gear idler shaft.