mtx75 Manual Transmission
mtx75 Manual Transmission
mtx75 Manual Transmission
2002 TRANSMISSION
SPECIFICATIONS
TRANSAXLE RATIOS
2.0L Zetec-E Engine
1st gear 3.667
2nd gear 2.136
3rd gear 1.448
4th gear 1.028
5th gear 0.767
Reverse gear 3.727
Final drive 3.820
TORQUE SPECIFICATIONS
Description Nm lb-ft lb-in
Transaxle to engine flange bolts 47 35 -
Starter motor to transaxle housing 35 26 -
Intermediate shaft center bearing 25 18 -
Engine rear mount bracket to transaxle 80 59 -
Engine rear mount (four nuts) 48 35 -
Engine rear mount (center nut) 133 98 -
Roll restrictor to transaxle 48 35 -
Roll restrictor to subframe 48 35 -
Catalytic converter to exhaust 47 35 -
Lower suspension arm ball joint to spindle carrier 47 35 -
Suspension strut top mount retaining nuts 25 18 -
Clutch slave cylinder to transaxle 10 - 89
Transaxle housing flange bolts 32 24 -
Reverse gear idler shaft mounting 34 25 -
Spur gear to differential 88 65 -
Selector finger to selector shaft 28 21 -
Selector gate to housing 10 - 89
Gearshift lever to selector shaft 40 30 -
Transmission fluid drain plug 45 33 -
Transmission fluid filler plug 45 33 -
Reversing lamp switch 10 - 89
Ball joint to selector lever shaft 15 11 -
Gearshift lever to gearshift lever shaft 30 22 -
Cover of internal selector mechanism 10 - 89
Reversing light actuating pin 25 18 -
Reverse gear idler shaft 24 18 -
Selector mechanism to transaxle 23 17 -
Battery tray to body 25 18 -
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2002 TRANSMISSION Manual Transmission/Transaxle - Vehicles With MTX75/Manual Transaxle - Focus
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2002 TRANSMISSION Manual Transmission/Transaxle - Vehicles With MTX75/Manual Transaxle - Focus
MTX-75 means:
M: Manual
T: Transmission
X: Transaxle (front wheel drive)
75: Distance between input and output shaft in mm.
The aluminum transaxle housing comprises two closed sections. Additional reinforcement ribbing
has been added to the transaxle housing to reduce noise and vibrations.
All the gear wheels in the "2-shaft transaxle" are in constant mesh. In each gear the required
transaxle ratio is achieved by means of a pair of gear wheels.
When reverse gear is selected, an idler gear changes the direction of rotation of the output shaft.
To further improve stability and gear shifting, the selector mechanism has been revised to
incorporate a maintenance-free cable operating mechanism.
All the gear wheels, including reverse gear, are bevel-cut, synchronized and run on needle roller
bearings.
The first, second and third gears (vehicles built up to 08/2000) are dual-synchronized.
Input and Output Shaft
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2002 TRANSMISSION Manual Transmission/Transaxle - Vehicles With MTX75/Manual Transaxle - Focus
In neutral, none of the gears are connected to the input or output shaft via the relevant
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2002 TRANSMISSION Manual Transmission/Transaxle - Vehicles With MTX75/Manual Transaxle - Focus
The input and output shafts are each seated in one roller bearing in the transaxle housing section
on the clutch side and one roller bearing in the transaxle housing section on the transaxle side.
The output drive pinion is in constant mesh with the differential drive annulus.
The third and fourth gear wheels and the third and fourth gear synchronizer are located on the
input shaft. The gearing for first, second and reverse gears is an integral part of the input shaft.
The first, second, fifth and reverse gearwheels and the first and second gear synchronizer and fifth
and reverse gear synchronizer are located on the output shaft. On vehicles built up to 07/2000 the
gearing for third and fourth gear is an integral part of the output shaft.
Differential
The transaxle and differential are installed in a two-part aluminum housing which is flange-
mounted to the engine.
The input shafts have serrated teeth and are secured with a snap ring.
The torque is transmitted from the spur gear to the input shafts via two differential pinions
mounted on the differential pinion shaft and the input shaft pinions.
When cornering, the drive gears need to turn at different speeds as the road wheels travel
different distances. This is achieved by means of the differential pinions which turn on their own
shaft and mesh with the input shaft pinions turning at different rates.
Power Flow
First Gear
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The reverse gear idler is driven by the input shaft. Its function is to reverse the direction of
rotation of the output shaft in reverse gear.
The reverse gear idler is located on the idler gear shaft together with a needle roller bearing.
Selector Interlock Mechanism
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2002 TRANSMISSION Manual Transmission/Transaxle - Vehicles With MTX75/Manual Transaxle - Focus
The selector interlock mechanism and the selector finger are mounted on a sleeve in the selector
mechanism housing and keep the selected gear engaged with the aid of a spring-loaded ball until
another gear is selected.
The reversing lamp switch is mounted on the side of the selector mechanism housing.
General Illustrations
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2002 TRANSMISSION Manual Transmission/Transaxle - Vehicles With MTX75/Manual Transaxle - Focus
Fig. 13: Identifying Input Shaft Components Description - Vehicles Built Up To 08/2001
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Fig. 14: Identifying Input Shaft Components Description - Vehicles Built 08/2001
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2002 TRANSMISSION Manual Transmission/Transaxle - Vehicles With MTX75/Manual Transaxle - Focus
Onwards
Courtesy of FORD MOTOR CO.
Third, Fourth, Fifth and Reverse Gear Output Shaft - Vehicles built up to 07/2000
Fig. 15: Identifying Third, Fourth, Fifth And Reverse Gear Output Shaft Components
Description - Vehicles Built Up To 07/2000
Courtesy of FORD MOTOR CO.
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Fig. 16: Identifying First And Second Gear Output Shaft Components Description -
Vehicles Built Up To 07/2000
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Fig. 17: Identifying Output Shaft Components Description - Vehicles Built 08/2000
Onwards
Courtesy of FORD MOTOR CO.
Selector Mechanism - Vehicles built up to 01/2000
01/2000
Courtesy of FORD MOTOR CO.
Selector Mechanism Housing - Vehicles built up to 01/2000
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Fig. 20: Identifying Selector Gate Components Description - Vehicles Built Up To 01/2000
Courtesy of FORD MOTOR CO.
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GENERAL PROCEDURES
DRAIN PROCEDURE
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FILL PROCEDURE
Material
MATERIAL SPECIFICATION
Manual transmission fluid WSD-M2C200-C
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3. Fill the transaxle to 0-5mm below the lower edge of the filler plug bore.
Fill with manual transmission fluid.
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BEARING CHECK
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2002 TRANSMISSION Manual Transmission/Transaxle - Vehicles With MTX75/Manual Transaxle - Focus
1. Check whether the bearing cage is damaged at the top, side or at the openings is damaged
because of the unprofessional use of a special tool or of the wrong tool.
Install a new bearing if necessary.
2. Check whether the ends of the taper rollers are discolored as a result of inadequate
lubrication or overheating, possibly through excessive pre-load.
Install a new bearing and new seals if necessary.
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3. Check whether the ends of the taper rollers are worn away due to incorrect installation,
excessive pre-load or faulty bearing seating.
Install a new bearing and new seals if necessary.
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4. Check whether the bearing surfaces are grey or grey/black with deposits between the
rollers.
Install a new bearing and new seals if necessary.
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5. Check whether the bearing ring surfaces are grooved caused by static impact.
Install a new bearing if its surface is rough, or if it is noisy.
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6. Check for a dark blue color caused by overheating (yellow or brown is normal) due to
excessive preload or inadequate lubrication.
Install a new bearing, new seals and check other components as necessary.
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Fig. 32: Checking Bearing Surfaces For Abrasion Due To Metal Fatigue
Courtesy of FORD MOTOR CO.
IN-VEHICLE REPAIR
HALFSHAFT SEAL LH
Special Tool(s)
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HALFSHAFT SEAL LH
Special Tool(s)
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MATERIAL SPECIFICATIONS
Manual transmission fluid WSD-M2C200-C
Removal
1. Loosen the strut and spring assembly top mount nuts by five turns (left-hand side shown).
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Fig. 37: Loosening Strut And Spring Assembly Top Mount Nuts
Courtesy of FORD MOTOR CO.
CAUTION: Protect the ball joint seal using a soft cloth to prevent
damage.
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2002 TRANSMISSION Manual Transmission/Transaxle - Vehicles With MTX75/Manual Transaxle - Focus
3. Detach the lower arm ball joint from the wheel knuckle.
1. Remove the bolt
2. Detach the lower arm ball joint
4. Remove the intermediate shaft center bearing retaining nuts and cap.
Discard the cap and nuts
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Fig. 39: Removing Intermediate Shaft Center Bearing Retaining Nuts And Cap
Courtesy of FORD MOTOR CO.
CAUTION: Support the halfshaft. The inner joint must not bent more
than 18 degrees. The outer joint must be bent more than
45 degrees.
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5. Detach the intermediate shaft and halfshaft from the transaxle and secure it to one side.
Allow the oil to drain into a suitable container.
6. Using the special tools, remove the halfshaft oil seal (left-hand side shown right-hand side
similar).
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CAUTION: Support the halfshaft. The inner joint must not bent more
than 18 degrees. The outer joint must be bent more than
45 degrees.
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2002 TRANSMISSION Manual Transmission/Transaxle - Vehicles With MTX75/Manual Transaxle - Focus
NOTE: Install a new intermediate shaft center bearing cap and nuts.
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Fig. 44: Identifying Tightening Torque Of Intermediate Shaft Center Bearing Cap
Courtesy of FORD MOTOR CO.
CAUTION: Protect the ball joint seal using a soft cloth to prevent
damage.
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NOTE: The fill height is 5 - 10 mm below the lower edge of the filler
hole.
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5. Check the transaxle fluid level and top up with Manual transmission fluid if necessary.
6. Lower the vehicle.
7. Tighten the strut and spring assembly top mount nuts.
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Fig. 47: Identifying Tightening Torque Of Strut And Spring Assembly Top Mount
Nuts
Courtesy of FORD MOTOR CO.
REMOVAL
TRANSAXLE
Special Tool(s)
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GENERAL EQUIPMENT
Retaining strap
Transmission jack
Removal
1. General Notes.
Operations for particular variants which do not apply to all vehicles are marked
clearly with a note.
If necessary, remove the cable ties and install new ones when reinstalling the assembly.
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6. Loosen the strut and spring assembly top mount nuts by five turns on both sides.
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Fig. 52: Loosening Strut And Spring Assembly Top Mount Nuts
Courtesy of FORD MOTOR CO.
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CAUTION: Protect the ball joint seal using a soft cloth to prevent
damage.
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2002 TRANSMISSION Manual Transmission/Transaxle - Vehicles With MTX75/Manual Transaxle - Focus
CAUTION: Support the halfshaft. The inner joint must not be bent
more than 18 degrees. The outer joint must not be bent
more than 45 degrees.
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2002 TRANSMISSION Manual Transmission/Transaxle - Vehicles With MTX75/Manual Transaxle - Focus
CAUTION: Support the halfshaft. The inner joint must not be bent
more than 18 degrees. The outer joint must not be bent
more than 45 degrees.
CAUTION: Cap the transaxle to prevent oil loss and dirt ingress.
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Fig. 61: Detaching Right-Hand Halfshaft Together With Intermediate Shaft From
Transaxle
Courtesy of FORD MOTOR CO.
17. Detach the right-hand halfshaft together with the intermediate shaft from the transaxle and
secure it to one side.
CAUTION: Support the halfshaft. The inner joint must not be bent
more than 18 degrees. The outer joint must not be bent
more than 45 degrees.
CAUTION: Cap the transaxle to prevent oil loss and dirt ingress.
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18. Using the special tool, detach the left-hand halfshaft from the transaxle and secure it to one
side.
Discard the snap ring.
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Remove the supply line and secure it to one side using cable ties.
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25. Using the special tools, lower the engine and transaxle assembly slightly.
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31. Push the engine and transaxle assembly forwards and insert an approximately 350 mm long
wooden block between the engine and the crossmember.
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32. Position a suitable transmission jack under the transaxle and secure it with a retaining strap.
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35. Remove the transaxle from the engine and lower it using a transmission jack.
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DISASSEMBLY
TRANSAXLE
Special Tool(s)
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3. Clean any grease and foreign material from the input shaft.
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11. Remove the selector rods and the first and second gear selector fork.
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Fig. 87: Removing Selector Rods And First And Second Gear Selector Fork
Courtesy of FORD MOTOR CO.
MY
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MY
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Remove the bearing, reverse idler gear, needle roller bearing and thrust washers.
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15. Using the special tools, remove the differential bearing outer race.
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16. Using the special tools, remove the bearing outer races from the input and output shaft.
MY
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Fig. 92: Removing Bearing Outer Races From Input And Output Shaft
Courtesy of FORD MOTOR CO.
17. Using the special tools, remove the bearing outer races and shims from the differential and
input shaft.
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2002 Ford Focus LX
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Fig. 93: Removing Bearing Outer Races And Shims From Differential And Input
Shaft
Courtesy of FORD MOTOR CO.
18. Using the special tools, remove the output shaft bearing outer race and shim.
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Fig. 94: Removing Output Shaft Bearing Outer Race And Shim
Courtesy of FORD MOTOR CO.
NOTE: Only remove the reverse gear idler shaft if there is evidence of
damage or leaks.
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NOTE: Only remove the reverse gear idler shaft if there is evidence of
damage or leaks.
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20. Using a wooden drift, remove the reverse gear idler shaft.
General Equipment
GENERAL EQUIPMENT
Hot air blower
Material
MATERIAL SPECIFICATIONS
Sealer ESDM-1G220-A
MY
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Sealer WSK-M2G348-A5
Disassembly
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3. Remove the gearshift lever and the cover of the internal selector mechanism.
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Fig. 99: Removing Gearshift Lever And Cover Of Internal Selector Mechanism
Courtesy of FORD MOTOR CO.
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4. Loosen the bolt and remove the gearshift and selector lever shaft guide.
Heat the bolt to approx. 60 to 80°C using a hot air blower and remove it.
5. Remove the selector block and the spring, remove the shift lever.
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6. Remove the selector gate and selector shaft from the selector mechanism housing.
1. Remove the bolt.
2. Remove the selector gate with the selector shaft.
Remove the spring.
MY
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Fig. 102: Removing Selector Gate And Selector Shaft From Selector Mechanism
Housing
Courtesy of FORD MOTOR CO.
MY
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MY
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MY
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MY
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11. Drive both the needle roller bearings of the gearshift lever shaft inwards using a suitable
socket and remove them.
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1. Drive in the upper needle roller bearing of the gearshift lever shaft using a suitable socket.
MY
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Fig. 108: Driving In Upper Needle Roller Bearing Of Gearshift Lever Shaft
Courtesy of FORD MOTOR CO.
2. Drive in the oil seal as far as the stop using a suitable socket.
MY
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3. Install the lower needle roller bearing of the gearshift lever shaft together with the gearshift
lever shaft.
MY
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Fig. 110: Installing Lower Needle Roller Bearing Of Gearshift Lever Shaft Together
With Gearshift Lever Shaft
Courtesy of FORD MOTOR CO.
4. Set the end float on the gearshift lever shaft to 0.3 +/- 0.1 mm by tapping lightly.
MY
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MY
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6. Assemble the selector finger and bracket, insert it in the selector gate.
1. Selector finger
2. Selector finger bracket
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MY
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Fig. 115: Installing Selector Gate And Selector Shaft To Selector Mechanism
Housing
Courtesy of FORD MOTOR CO.
MY
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10. Install the selector lever shaft and the ball bearing.
MY
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11. Install the cover of the inner gearshift mechanism using sealer.
MY
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MY
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INPUT SHAFT
Special Tool(s)
MY
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MATERIAL SPECIFICATIONS
Manual transmission fluid WSD-M2C200-C
Disassembly
CAUTION: The inner synchronizer ring and the synchronizer cone must
be handled very carefully.
1. General note
If there any new installation of bearings, shafts or the transaxle housings is necessary,
the transaxle must be shimmed.
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2. Using the special tool, remove the clutch housing roller bearing.
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3. Using the special tool, remove the transaxle housing roller bearing.
4. Using the special tool, press off the fifth gear wheel.
1. Discard the snap ring.
2. Press off the fifth gear wheel.
5. Remove the fourth gear wheel.
1. Remove the fourth gear wheel.
2. Remove the needle roller bearing.
3. Remove the synchronizer ring.
MY
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MY
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NOTE: Take care when pulling the selector ring off the gear
synchronizer hub. The detent balls are spring-loaded.
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NOTE: Do not oil taper roller bearings which are to be used again.
New taper roller bearings can be installed without any
treatment.
1. Carefully clean and check all sliding parts and lubricate them with clean manual
transmission fluid before assembly.
2. Using a length of suitable tube, install the clutch housing roller bearing.
MY
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MY
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NOTE: Do not oil taper roller bearings which are to be used again.
New taper roller bearings can be installed without any
treatment.
3. Install the selector ring the right way round and slide it on.
NOTE: Install the synchronizer hub with the large collar facing
outwards and the annular groove facing the small collar.
MY
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NOTE: Install the synchronizer hub with the large collar facing
outwards.
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MY
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MY
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9. Using a length of suitable tube, install the transaxle housing roller bearing.
MY
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MY
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OUTPUT SHAFT
Special Tool(s)
MATERIAL SPECIFICATIONS
Transmission Fluid WSD-M2C200-C
Disassembly
1. Using the special tool, remove the transaxle housing roller bearing.
MY
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MY
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Fig. 139: Removing Fifth Gear And Reverse Gear Synchronizer Hub Assembly
Courtesy of FORD MOTOR CO.
3. Remove the fifth gear and the reverse gear synchronizer hub assembly.
1. Remove the snap ring.
2. Remove the synchronizer hub assembly.
4. Remove the fifth gear wheel.
1. Remove the synchronizer ring.
2. Remove the fifth gear wheel.
3. Remove the needle roller bearing.
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NOTE: Use the special tool with the flat side upwards.
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NOTE: Use the special tool with the flat side upwards.
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6. Using the special tool, remove the second and the third gear wheel.
MY
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MY
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Fig. 144: Removing First And Second Gear Synchronizer Hub Assembly
Courtesy of FORD MOTOR CO.
MY
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MY
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10. Using the special tool, remove the clutch housing roller bearing.
CAUTION: Take care when removing the selector ring from the
synchronizer hub assembly. The detent balls are spring-
loaded.
MY
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1. Clean and check all parts thoroughly before assembling them and lubricate all sliding parts
with transmission fluid.
MY
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NOTE: Install the synchronizer hub assembly with the larger collar
facing outwards (towards the second gear wheel).
Fig. 150: Installing First And Second Gear Synchronizer Hub Assembly
Courtesy of FORD MOTOR CO.
4. Install the first and the second gear synchronizer hub assembly.
1. Install the synchronizer hub assembly.
2. Install the snap ring.
5. Install the second gear wheel.
1. Install the needle roller bearing.
MY
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NOTE: Install the synchronizer hub assembly with the small collar and
the ring groove facing outwards.
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Fig. 155: Identifying Reverse And Fifth Gear Synchronizer Hub Assembly
Installation Position
Courtesy of FORD MOTOR CO.
NOTE: Install the synchronizer hub assembly with the small collar and
the ring groove facing outwards.
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10. Install the fifth and the reverse gear synchronizer assembly.
1. Install the synchronizer hub assembly.
2. Install a new snap ring.
11. Install the reverse gear wheel.
1. Install the synchronizer ring.
2. Install the needle roller bearing.
3. Install the reverse gear wheel.
MY
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12. Using a length of suitable tube, install the transaxle housing roller bearing.
MY
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13. Using a length of suitable tube, install a new clutch housing roller bearing.
MY
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MY
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DIFFERENTIAL
Special Tool(s)
MATERIAL SPECIFICATIONS
Manual transmission fluid ESD-M2C186-A
Disassembly
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MY
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MY
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3. Using the special tools, preload the bearing and remove it.
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MY
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NOTE: Do not oil taper roller bearings which are to be used again.
New taper roller bearings can be installed without any
treatment.
1. Carefully clean and check all parts and lubricate them with Manual transmission fluid.
2. Install the gear to the differential.
Tighten the bolts, working diagonally.
MY
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ASSEMBLY
TRANSAXLE
Special Tool(s)
MATERIAL SPECIFICATIONS
Manual transmission fluid ESD-M2C186-A
Sealer WSK-M2G348-A5
Temperature reduction spray
High-temperature grease ESDM-1C220-A
Assembly
MY
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3. Using the special tools, install the bearing cups on the transaxle housing side.
Heat the housing area to approximately 80°C.
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CAUTION: Press the bearing races down again. The press pressure
must not exceed 15 kN.
5. Install the measuring shims and the bearing cups in the housing section at the clutch end.
Heat the housing area to approximately 80°C.
MY
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NOTE: Do not oil taper roller bearings which are to be used again.
New taper roller bearings can be installed without any
treatment.
MY
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7. Assemble the input and output shafts together and put them in the transaxle case as an
assembly.
NOTE: Do not oil taper roller bearings which are to be used again.
New taper roller bearings can be installed without any
treatment.
MY
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MY
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10. Using the special tool, prepare the input shaft for measuring.
Turn the input shaft back and forth to settle the bearings using the special tool.
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11. Install the special tool on the transaxle housing and set it to zero.
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13. Using the special tools, prepare the output shaft for measuring.
Turn the input shaft back and forth to settle the bearings using the special tool.
MY
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16. Using the special tools, prepare the differential for measuring.
Using the special tools, turn the output shaft back and forth and at the same time press
down.
Set up the special tool and set it to zero.
17. Using the special tools, measure the differential end float.
Note the resulting measurement.
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18. Select the correct shim(s) for the differential, input shaft and output shaft. Refer to
SPECIFICATIONS .
19. Using the special tools, remove the bearing outer races and shim of the differential, the input
shaft and the output shaft again.
Locate the special tool in the housing recesses.
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Fig. 185: Installing Selected Shims And Bearing Cups In Housing Section At Clutch
End
Courtesy of FORD MOTOR CO.
20. Install the selected shims and the bearing cups in the housing section at the clutch end.
Heat the housing area to approximately 80°C.
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NOTE: Make sure the fourth gear selector ring is in the neutral
position.
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23. Install the fifth/reverse gear selector fork and position it to the side.
24. Install the third/fourth gear selector fork.
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NOTE: When installed correctly, the selector rods are the same
height.
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NOTE: The transaxle housing must not be turned over to tighten the
bolts.
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Fig. 193: Identifying Tightening Torque Of Housing (Clutch End) Flange Bolt
Courtesy of FORD MOTOR CO.
NOTE: Make sure the transaxle is in neutral (the gearshift lever and
selector lever must be vertical).
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If the turning torque is too high, all the measurements (to establish the required shim
thickness) must be repeated.
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32. Using the special tools, install the differential oil seals.
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33. Coat the slave cylinder with sealer and install it together with a new seal.
34. Remove the adhesive tape from the input shaft splines.
35. Coat the input shaft splines with a thin layer of high-temperature grease.
INSTALLATION
TRANSAXLE
Special Tool(s)
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GENERAL EQUIPMENT
Retaining strap
Transmission jack
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Material
MATERIAL SPECIFICATIONS
Manual transmission fluid WSD-M2C200-C
Installation
1. General note.
Only use new self-locking nuts.
CAUTION: Make sure that the two locating tubes are installed.
3. Using a retaining strap and wooden blocks, secure the transaxle on a transmission jack.
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5. Push the engine forwards and install an approximately 350 mm long wooden block between
the engine and the crossmember.
Move the transaxle into position.
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Fig. 209: Identifying Tightening Torque Of Engine Rear Mount Bracket Bolts
Courtesy of FORD MOTOR CO.
15. Using the special tools, raise the engine and transaxle assembly slightly.
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CAUTION: Support the halfshaft. The inner joint must not be bent
more than 18 degrees. The outer joint must not be bent
more than 45 degrees.
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23. Attach the halfshaft together with the intermediate shaft to the transaxle.
CAUTION: Support the halfshaft. The inner joint must not be bent
more than 18 degrees. The outer joint must not be bent
more than 45 degrees.
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CAUTION: Support the halfshaft. The inner joint must not be bent
more than 18 degrees. The outer joint must not be bent
more than 45 degrees.
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35. Tighten the strut and spring assembly top mount nuts by five turns on both sides.
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Fig. 227: Identifying Tightening Torque Of Strut And Spring Assembly Top Mount
Nuts
Courtesy of FORD MOTOR CO.
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Carry out a road test to enable the powertrain control module (PCM) to collect data.
Check the routing of the vacuum hoses and wiring and secure them with cable ties.
Check the engine and cooling system for leaks (visual inspection).
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