MT 75 Manual Transmission and Clutch

09/97 Scorpio 95 00-01-1

Manual Transmission Overhaul (transmission removed) (16 118 8)
Special Tools
15030A
15-030A
Universal flange-holding
wrench
15035
15-035
Bearing ring installer
15036
15-036
Countershaft roller bearing
installer
15050A
15-050A
Remover (basic tool)
15064
15-064
Adaptor for 15035, bearing
cones
15068
15-068
Adaptor for 15033, bearing
cones
15091
15-091
Separator
15092
15-092
Bridge, remover
15096
15-096
Installer
PZ16040A
16-040A
Guide sleeve wrench
16041
16-041
Front transmission housing
remover and installer
1604101
16-041-01
Adaptor for 16-041
16042A
16-042-A
Adaptor for 16-042 A-01
16042A01
16-042A-01
Threaded spindle
16043A
16-043A
Drive flange oil seal installer
16044
16-044
Guide sleeve oil seal
installer
16045
16-045
Mounting bracket
16050
16-050
Collet for 15-050 A
16056
16-056
Remover
21036A
21-036A
Remover for pilot bearing
MT 75 Manual Transmission and Clutch
09/97 Scorpio 95 00-01-2
21037B
21-037B
Pilot bearing remover
21051
21-051
Oil seal remover
21103A
21-103A
Locator
21540
21-540
Angle gauge
Workshop Equipment
Assembly stand
Materials
Cable ties
Sealer ESKM-4G242-A
High-temperature
grease
ESDM-1C220-A
Transmission fluid ESDM-2C186-A
Proprietary Tools
Two-legged puller
Internal extractor
30 mm socket wrench (double hexagon)
8 mm Allen key
14 mm Allen key
17 mm Allen key
T40 Torx wrench
9,5 mm twist drill bit
Dismantle
1. General notes.
Some synchroniser units and bearings are
identical and must be marked for reuse.
Mark the synchroniser units in the direction
of travel of the vehicle.
All the bearings are paired and must not
be mixed up.
Use soft jaws for all operations in a vice.
D1601150
2. Drain off the transmission fluid
(transmission for diesel engine shown).
MT 75 Manual Transmission and Clutch
09/97 Scorpio 95 00-01-3
D1601151
16045
1
2
3. Mount the transmission on an assembly
stand.
1 Screw the tool bolt into the threaded hole for
the oil drain plug and tighten it.
2 Secure the mounting bracket to the
transmission.
1
2
D1601011
4. Detach the pressure line and the bleed
screw.
1 Pull out the spring clip; disconnect the
quick-release coupling.
2 Remove the bleed screw.
D1601012
5. Remove the slave cylinder complete with
the release bearing.
D1601153
15030 A
6. Unscrew the drive flange nut from the
mainshaft.
S Use a 30 mm socket wrench.
S Hold with the special tool.
S Discard the nut.
MT 75 Manual Transmission and Clutch
09/97 Scorpio 95 00-01-4
D1601160
15091
15092
7. Pull off the drive flange.
16040A
D1601154
8. Remove the guide sleeve.
Remove the thrust washer.
S1601148
Remove input shaft guide sleeve oil seal
9. Remove the radial oil seal.
Prise out the radial oil seal using a suitable
lever.
2
1
D1601155
10. Remove the input shaft circlip.
11. Remove the countershaft bearing
housing.
1 Remove the bearing housing locking plate.
2 Unscrew the bearing housing using a
17 mm Allen key.
MT 75 Manual Transmission and Clutch
09/97 Scorpio 95 00-01-5
D1601156
1
2
12. Remove the selector interlock
mechanism.
1 Remove the plug with a 14 mm Allen key.
2 Remove the spring, pin, ball and sleeve.
D1601157
2
1
13. Remove the reversing light switch and
the locking screw.
1 Reversing light switch
2 Locking plate locking screw.
D1601158
3
2
1
14. Unscrew the transmission housing bolts.
1 Housing flange (10 bolts).
2 Only slacken the bolt of the reverse gear
idler shaft (marked in blue).
3 Unscrew the bolt of the reverse gear idler
shaft (marked in blue).
D1601163
21051
15. Prise out the radial oil seal.
MT 75 Manual Transmission and Clutch
09/97 Scorpio 95 00-01-6
S1601149
16. Remove the speedometer drive pinion
and worm gear.
Remove the blanking cover.
J1601160
NOTE: Do not drive out the housing locating
dowels.
17. Separate the transmission housing
halves.
NOTE: Only apply the levers to the reinforcing
ribs.
D1601159
1604101
2
16041
1
D
CAUTION: Take care not to apply
excessive pressure to the input shaft
through the special tool as this could
damage the 4th gear synchroniser ring.
18. Pull off the front transmission housing.
NOTE: Hold the special tool with a drift.
1 Attach the puller.
2 Screw the adaptor into the threaded hole of
the guide sleeve.
S If necessary, assist with levers.
D1601161
1
2
19. Remove the 3rd/4th gear selector fork.
S Move the main selector shaft to the neutral
position.
1 Pull out the auxiliary selector shaft.
2 Remove the 3rd/4th gear selector fork.
MT 75 Manual Transmission and Clutch
09/97 Scorpio 95 00-01-7
J1601168
20. Remove the second retaining bolt of the
reverse gear idler shaft (marked in blue)
and the magnetic disc.
J1601169
D
CAUTION: Move the selector shaft to the
neutral position so that the locating pin
does not break off the shift finger holder.
NOTE: Locate the puller on the housing bosses.
21. Press the mainshaft out of the bearing in
the rear transmission housing.
22. Remove the main selector shaft with the
selector fork.
23. Lift out the complete gear train.
D1601164
1
2
Dismantle main selector shaft
NOTE: Catch the two balls from the spring
carrier.
24. Dismantle main selector shaft
1 Remove the circlip.
2 Remove the spring cup, spring and spring
carrier.
MT 75 Manual Transmission and Clutch
09/97 Scorpio 95 00-01-8
D1601165
3
2
1
25. Dismantle the main selector shaft
(continued).
1 Drive the roll pin out of the shift finger holder
and the main selector shaft.
2 Remove the shift finger holder.
3 Remove the 1st/2nd gear selector fork.
D1601166
3 1
2
26. Dismantle the main selector shaft
(continued).
1 Remove the locking sleeve.
2 Drive the roll pin out of the shift finger and
the main selector shaft.
3 Remove the shift finger.
J1601171
Dismantle rear transmission housing
27. Remove the countershaft rear roller
bearing.
Use a proprietary internal extractor.
D1601168
28. Remove the selector gate.
MT 75 Manual Transmission and Clutch
09/97 Scorpio 95 00-01-9
D1601169
21103 A
29. Drive out the main selector shaft ball
sleeve together with the radial oil seal.
D1601167
30. Unscrew the retaining bolts of the
mainshaft ball bearing.
D1601171
31. Remove the mainshaft ball bearing.
Drive out the mainshaft ball bearing using a
suitable length of tube.
D1601172
21036 A
21037 B
Dismantle front transmission housing
NOTE: Insert a spacer (approx. 63 mm) in the
hole.
NOTE: Use remover 21-036 A with the thrust
element of 21-037 B.
32. Remove the main selector shaft ball
sleeve.
MT 75 Manual Transmission and Clutch
09/97 Scorpio 95 00-01-10
D1601173
33. Remove the input shaft ball bearing.
Use a suitable length of tube or Special Tool
15-096.
S1601150
D
CAUTION: Take care not to damage the
bearing housing thread in the housing.
34. Drive out the countershaft roller bearing.
Dismantle mainshaft
35. General notes.
D
CAUTION: From build date 17.8.1994
onwards (see table on page 2, General
Specifications) the synchroniser rings for
1st, 2nd and 3rd gear have a taper angle
of 7 and are coated with molybdenum.
The synchroniser rings for 4th, 5th and
reverse gear have a taper angle of 6,5
as previously.
Vehicles manufactured from build date
17. 6.1996 are fitted with a 1st/2nd gear
double synchroniser unit.
When the shaft is dismantled, the
synchroniser rings and synchroniser units
must be marked.
When dismantling the synchroniser units,
also mark the synchroniser hubs in relation
to the shift rings.
MT 75 Manual Transmission and Clutch
09/97 Scorpio 95 00-01-11
J1601179
1
3
2
36. Remove the input shaft with the 4th gear
synchroniser ring from the mainshaft.
1 Input shaft
2 4th gear synchroniser ring
3 Roller bearing
J1601180
2
1
37. Remove the 5th gear wheel with the
synchroniser ring from the mainshaft.
1 5th gear wheel
2 Needle roller bearing
J1601182
3
1
2
:
WARNING: The synchroniser units must
not be allowed to fall apart as there is a
danger of injury from springs, blocker bars
and balls.
38. Remove the 3rd/4th gear synchroniser
unit with the 3rd gear wheel.
S Clamp the mainshaft in a vice with the
output shaft pointing downwards.
S Remove the circlip.
1 3rd/4th gear synchroniser unit
2 3rd/4th gear wheel
3 Needle roller bearing
MT 75 Manual Transmission and Clutch
09/97 Scorpio 95 00-01-12
J1601183
16056
39. Pull off the 3rd gear bearing ring.
Locate the puller in the recesses in the
bearing ring.
J1601184
NOTE: Mark the parts.
40. Remove the 2nd gear wheel with the
needle roller bearing and synchroniser
ring.
MT 75 Manual Transmission and Clutch
09/97 Scorpio 95 00-01-13
1
2
3
ELS1601195
Vehicles manufactured from build date
17. 6. 1996 are fitted with a 1st/2nd gear
synchroniser unit.
NOTE: Mark the shift ring for the gear
synchroniser. Components are paired.
41. Remove the 1st/2nd gear synchroniser
unit with the 1st gear wheel.
S Remove the circlip for the 1st/2nd gear
synchroniser unit.
1 1st/2nd gear synchroniser unit
2 1st gear wheel
3 Needle roller bearing
MT 75 Manual Transmission and Clutch
09/97 Scorpio 95 00-01-14
J1601188
1
2
3
NOTE: Mark the shift ring for the gear
synchroniser. The components are paired.
42. Remove the 5th/reverse gear
synchroniser unit with the reverse gear
wheel and needle roller bearing.
S Clamp the mainshaft the other way round in
the vice.
S Circlip
1 Synchroniser unit
2 Reverse gear wheel
3 Needle roller bearing
ELS1601194
4
3 1
2
1
5
:
WARNING: Take care when removing the
shift ring from the synchroniser hub. The
balls and blocker bars are spring-loaded.
43. Dismantle the synchroniser unit.
1 Synchroniser rings
2 Shift ring
3 Synchroniser hub
4 Ball and blocker bar
5 Compression spring
MT 75 Manual Transmission and Clutch
09/97 Scorpio 95 00-01-15
ELS1601193
3 2 1
4
Vehicles manufactured from built date
17. 6.1996 are fitted with a 1st/2nd gear double
synchroniser unit.
44. Double synchroniser unit components.
1 Outer synchroniser ring
2 Inner synchroniser ring
3 Synchroniser cone
4 Gear wheel
J1601190
15050 A
16050
Dismantle countershaft
NOTE: Insert the puller in the annular groove
provided in the ring.
45. Pull the inner ring off the countershaft.
J1601191
4
3 1
2
Dismantle reverse gear idler shaft
46. Dismantle the reverse gear idler shaft.
1 Drive out the roll pin.
2 Bearing housing
3 Idler
4 Needle roller bearing
MT 75 Manual Transmission and Clutch
09/97 Scorpio 95 00-01-16
J1601707
Assemble transmission
47. General notes.
S Lubricate all moving parts with transmission
fluid before or during assembly.
S Renew all the circlips, oil seals and
self-locking nuts.
S Measure the circlips so that they fit into their
grooves without free play.
48. Preparatory operations.
Clean and check all parts thoroughly and
renew if necessary.
69,0 mm 0,3 mm
D1601675
Assemble rear transmission housing
NOTE: If the rear transmission housing is
renewed, a new detent pin must be fitted.
The distance from the tip of the detent pin to the
housing mating face must be 69,0 0,3 mm.
D1601671
15068
15035
15035
15064
49. Fit the mainshaft ball bearing.
Use only the spindle of 15-035.
MT 75 Manual Transmission and Clutch
09/97 Scorpio 95 00-01-17
D1601667
24 Nm
50. Secure the mainshaft ball bearing with
bolts and washers.
D1601169
21103 A
51. Drive in the main selector shaft ball
sleeve flush.
D1601670
52. Fit the main selector shaft radial oil seal.
D1601668
10 Nm
NOTE: Use new locating bolts.
53. Fit the selector gate.
MT 75 Manual Transmission and Clutch
09/97 Scorpio 95 00-01-18
D1601179
15036
54. Drive in the countershaft roller bearing as
far as the stop.
2
15064
PZJ1601677
1
Assemble front transmission housing
55. Fit the input shaft ball bearing.
1 Fit the circlip in the annular groove of the
ball bearing.
2 Drive in the ball bearing from the clutch side
J1601678
15036
2,0 mm
NOTE: Do not drive the roller bearing in flush
but allow it to protrude approx. 2 mm on the
inside.
56. Fit the countershaft roller bearing.
D1601672
21103 A
57. Drive in the main selector shaft ball
sleeve flush.
MT 75 Manual Transmission and Clutch
09/97 Scorpio 95 00-01-19
S1601648
16044
Install input shaft guide sleeve oil seal
NOTE: The sealing lip must face the tool on
installation.
58. Drive in the radial oil seal.
J1601706
1
2 4
3
Assemble reverse gear idler shaft
NOTE: Do not fit the bearing housing twisted.
The threaded holes must line up with one
another.
59. Assemble the reverse gear idler shaft.
1 Needle roller bearing
2 Idler
3 Bearing housing
4 Drive in the roll pin.
J1601690
Assemble countershaft
60. Fit the bearing rings.
Heat the bearing rings to approx. 100C and
slide them on.
D1601666
1 2
Assemble main selector shaft
NOTE: The shift finger must point in the
opposite direction to the actuating pin of the
reversing light switch.
61. Assemble main selector shaft
1 Slide the shift finger onto the main selector
shaft and secure it with a roll pin.
2 Slide the locking sleeve onto the selector
shaft and shift finger.
MT 75 Manual Transmission and Clutch
09/97 Scorpio 95 00-01-20
D1601665
1
2
NOTE: The roll pin must be aligned centrally.
62. Assemble the selector shaft (continued).
1 Fit the 1st/2nd gear selector fork on the
selector shaft.
2 Slide the shift finger holder onto the selector
shaft and secure it with a roll pin.
D1601664
3
1
2
63. Assemble the main selector shaft
(continued).
1 Fit the spring carrier on the selector shaft
with two balls.
2 Fit the spring and spring cup.
3 Secure them with a circlip.
ELS1601194
4
3 1
2
1
5
Assemble mainshaft
64. Assemble the synchroniser unit.
1 Fit the compression springs.
2 Synchroniser hub
3 Ball and blocker bar
4 Position the shift ring correctly and slide it
on.
5 Fit the synchroniser rings.
MT 75 Manual Transmission and Clutch
09/97 Scorpio 95 00-01-21
PZJ1601694
2
1
3
NOTE: Marking
65. Fit the needle roller bearing and reverse
gear wheel with the synchroniser unit.
S Clamp the mainshaft in a vice with the
output end pointing upwards.
1 Reverse gear wheel
2 Synchroniser unit
3 Select a circlip which fits without free play
and fit it.
S Available circlips:
2,03 mm
2,07 mm
2,11 mm
2,15 mm
J1601686
3
2
1
Vehicles manufactured from build date
17. 6. 1996 are fitted with a 1st/2nd gear double
synchroniser unit.
NOTE: Marking
66. Fit the 1st/2nd gear synchroniser unit.
S Clamp the mainshaft the other way round.
1 Fit the needle roller bearing.
2 Fit the 1st gear wheel.
3 Fit the 1st/2nd gear synchroniser unit.
S Select a circlip which fits without free play
and fit it.
S Available circlips:
2,03 mm
2,07 mm
2,11 mm
2,15 mm
MT 75 Manual Transmission and Clutch
09/97 Scorpio 95 00-01-22
J1601684
1
2
3
67. Fit the synchroniser ring, needle roller
bearing and 2nd gear wheel.
1 Needle roller bearing
2 Synchroniser ring
3 2nd gear wheel
J1601683
NOTE: Slide the inner bearing ring onto the
mainshaft as far as the shoulder.
68. Fit the 3rd gear wheel inner bearing ring.
Heat the inner bearing ring to approx.
100C.
J1601682
2
1
NOTE: Fit the synchroniser unit with the small
collar facing upwards.
69. Fit the 3rd/4th gear synchroniser unit.
S Fit the needle roller bearing.
1 Fit the 3rd gear wheel.
2 Fit the 3rd/4th gear synchroniser unit.
S Select a circlip which fits without free play
and fit it.
S Available circlips:
1,99 mm
2,03 mm
2,07 mm
2,11 mm
2,15 mm
2,19 mm
MT 75 Manual Transmission and Clutch
09/97 Scorpio 95 00-01-23
J1601680
1
3
2
70. Fit the 5th gear wheel.
S Clamp the mainshaft the other way round.
1 Needle roller bearing
2 5th gear synchroniser ring
3 5th gear wheel
J1601679
2
3
1
71. Fit the input shaft.
S Clamp the mainshaft the other way round.
1 Roller bearing
2 4th gear synchroniser ring
3 Input shaft
D1601677
72. Assemble the countershaft with the
mainshaft and secure the assembly with
a cable tie.
D1601676
NOTE: The 1st/2nd gear selector fork must
engage in the 1st/2nd gear synchroniser unit in
the middle.
73. Fit the main selector shaft.
MT 75 Manual Transmission and Clutch
09/97 Scorpio 95 00-01-24
D1601679
74. Assemble the reverse gear idler with the
countershaft and mainshaft assembly.
S The end of the shaft with the flat points
upwards.
S Secure the assembly with a cable tie.
D1601678
75. Fit the 5th/reverse gear selector fork in
the lower synchroniser unit.
The outrigger points upwards.
D1601681
76. Fit the complete gear assembly in the
rear transmission housing.
77. Slide the speedometer worm gear onto
the mainshaft.
MT 75 Manual Transmission and Clutch
09/97 Scorpio 95 00-01-25
D1601682
16042 A
16042 A01
2
1
NOTE: During installation, guide the main
selector shaft into the ball sleeve correctly.
NOTE: The distance between the countershaft
and the synchroniser ring must not be zero.
78. Draw the mainshaft into the rear
transmission housing.
1 Screw the spindle into the mainshaft.
2 Fit the adaptor.
S Guide the countershaft into the rear roller
bearing.
79. Remove the speedometer worm gear.
J1601168
80. Insert the retaining bolt for the reverse
gear idler shaft and screw it up finger
tight.
S Remove the cable ties from the gear
assembly.
S Fit the magnetic disc.
D1601661
NOTE: The chamfered end of the selector shaft
points upwards.
81. Fit the 3rd/4th gear selector fork in the
upper synchroniser unit and the auxiliary
selector shaft.
MT 75 Manual Transmission and Clutch
09/97 Scorpio 95 00-01-26
J1601703
82. Fit the front transmission housing.
Position three spacers approx. 25 mm in
length between the housing sections.
D1601659
16041
2 3
1 1604101
83. Draw on the front transmission housing.
1 Attach the adaptor.
2 Attach the two clamping shells to the input
shaft.
3 Secure them with the sleeve.
D1601662
2
16041
1
NOTE: During installation, guide the
countershaft correctly into the bearing.
Tighten the flange bolts within 15 minutes.
84. Draw on the front transmission housing
(continued).
1 Slide the large sleeve over the clamping
shells and sleeve.
S Remove the spacers and apply sealer to the
mating faces of the rear transmission
housing.
S Apply sealer (ESKM-4G242-A) to the inside
of the mating faces.
2 Draw on the housing.
MT 75 Manual Transmission and Clutch
09/97 Scorpio 95 00-01-27
D1601658
1
24 Nm
2
32 Nm
85. Bolt the housing halves together.
1 Insert two housing bolts on opposite sides
and draw the housing sections together.
S Fit the remaining eight bolts and tighten
them.
2 Tighten the bolts of the reverse gear idler
shaft (both bolts are marked in blue).
D1601657
1 33 Nm
2
14 Nm
86. Fit the reversing light switch and the
locking screw.
1 Reversing light switch
2 Locking plate locking screw
D1601656
1
24 Nm
2
87. Fit the selector interlock mechanism.
1 Insert the sleeve, ball, pin and spring.
2 Apply sealer (ESKM-4G242-A) and screw in
the plug (14 mm Allen key).
S1601649
88. Fit the speedometer worm gear.
89. Fit the speedometer drive pinion in the
rear transmission housing.
Apply sealer (ESKM-4G242-A) and fit the
speedometer drive pinion cap.
MT 75 Manual Transmission and Clutch
09/97 Scorpio 95 00-01-28
D1601683
16043 A
90. Fit the drive flange radial oil seal.
2
D1601660
16042 A
1
16042 A01
91. Draw the drive flange onto the mainshaft.
S Fit the flange.
1 Screw the spindle into the mainshaft.
2 Screw on the adaptor.
S Hold the spindle with a drift.
D1601653
15030 A
200 Nm
92. Secure the drive flange with a new nut.
Hold the drive flange.
D1601655
93. Fit the input shaft circlip.
S Select a circlip which fits without free play
and fit it.
S Available circlips:
2,26 mm
2,30 mm
2,34 mm
2,38 mm
2,42 mm
MT 75 Manual Transmission and Clutch
09/97 Scorpio 95 00-01-29
S1601651
2
1
94. Prepare the guide sleeve for installation.
1 Fit a new O-ring.
2 Stick the thrust washer in place with grease.
16040A
S1601652
250 Nm
95. Secure the guide sleeve.
S1601653
40 Nm
96. Fit the countershaft bearing housing
using a new O-ring.
S Grease the O-ring.
S Screw in the bearing housing with a 17-mm
Allen key.
S1601654
21540
80
97. Unscrew the bearing housing 80.
MT 75 Manual Transmission and Clutch
09/97 Scorpio 95 00-01-30
S1601655
NOTE: Tilt the clutch housing downwards at
least 45.
98. Drive the countershaft bearing home
against the bearing housing.
Strike two blows on each of the bosses
using a brass drift and hammer. This will
drive the bearing home against the bearing
housing.
min. 6 Nm
21540
25 Nm
S1601656
20
D
CAUTION: A minimum torque of 6 Nm
must be achieved.
99. Tighten the bearing housing 20 and
secure it with the locking plate.
If the 6 Nm are not achieved,
sub-operations 97. to 99. must be repeated.
10 Nm
D1601512
100. Fit the slave cylinder complete with the
release bearing.
1
2
D1601511
NOTE: Make sure that the quick-release
coupling is locked securely.
101. Fit the clutch pressure line and bleed
screw.
1 Connect the quick-release coupling.
2 Screw in the bleed screw.
MT 75 Manual Transmission and Clutch
09/97 Scorpio 95 00-01-31
D1601650
35 Nm
102. Detach the transmission from the
assembly stand and detach the mounting
bracket.
103. Tighten the oil drain plug.