Manual Transmission/ Transaxle Repair

Transcription

1 Manual Transmission/ Transaxle Repair 36 - Manual Transmission & Drivetrain Student Guide FCS REF Course Code: 36S12T0 August 2007 Ford Customer Service Division Technical Training

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3 IMPORTANT SAFETY NOTICE Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles, as well as the personal safety of the individual doing the work. This manual provides general directions for accomplishing service and repair work with tested, effective techniques. Following them will help assure reliability. There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual doing the work. This manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Accordingly, anyone who departs from instructions provided in this manual must first establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods, tools or parts. As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each one is there for a specific purpose. NOTES give you added information that will help you to complete a particular procedure. CAUTIONS are given to prevent you from making an error that could damage the vehicle. WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury. The following list contains some general WARNINGS that you should follow when you work on a vehicle. Always wear safety glasses for eye protection. Use safety stands whenever a procedure requires you to be under the vehicle. Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure. Set the parking brake when working on the vehicle. If you have an automatic transmission, set it in PARK unless instructed otherwise for a specific service operation. If you have a manual transmission it should be in REVERSE (engine OFF) or NEUTRAL (engine ON) unless instructed otherwise for a specific service operation. Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide. Keep yourself and your clothing away from moving parts when the engine is running, especially the fan and belts. To help prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. Do not smoke while working on the vehicle. To help avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle. Tie long hair securely behind your head. Keep hands and other objects clear of the radiator fan blades. Electric cooling fans can start to operate at any time by an increase in underhood temperatures, even though the ignition is in the OFF position. Therefore, care should be taken to ensure that the electric cooling fan is completely disconnected when working under the hood. The recommendations and suggestions contained in this manual are made to assist the dealer in improving his dealership parts and/or service department operations. These recommendations and suggestions do not supersede or override the provisions of the Warranty and Policy Manual, and in any cases where there may be a conflict, the provisions of the Warranty and Policy Manual shall govern. The descriptions, testing procedures, and specifications in this handbook were in effect at the time the handbook was approved for printing. Ford Motor Company reserves the right to discontinue models at any time, or change specifications, design, or testing procedures without notice and without incurring obligation. Any reference to brand names in this manual is intended merely as an example of the types of tools, lubricants, materials, etc. recommended for use. Equivalents, if available, may be used. The right is reserved to make changes at any time without notice. DANGER: Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure to excessive amounts of dust may be a potential cancer and lung disease hazard. Exposure may also cause irritation to skin, eyes, and respiratory tract, may cause allergic reactions, and/or may lead to other chronic health effects. Do not breathe dust. Do not use compressed air to blow dust from storage containers or friction components. A high-efficiency (HEPA) vacuum cleaner should be used carefully to remove dust. Adherent dust should be removed with a damp rag. If inhaled, remove to fresh air. If irritation persists, seek medical attention or advice. If dust gets in eyes, irrigate under eyelids with water for 15 minutes and seek medical attention. Copyright 2007 Ford Motor Company Produced and Coodinated by Technical Support Operations Ford Customer Service Division August 2007

4 M CUSTOMER EXPECTATIONS Customer Expectations: Service 1. Make it convenient to have my vehicle serviced at your dealership. 2. The Service Advisor should demonstrate a genuine concern for my service needs. 3. Fix it right the first time, on time. 4. Complete servicing my vehicle in a timely and professional manner. 5. Provide me with a clear and thorough explanation of the service performed. 6. Call me within a reasonable amount of time after my service visit to ensure that I'm completely satisfied. 7. Be responsive to questions or concerns that I bring to your attention. Expectation #3 Fix It Right the First Time, on Time. Both service advisors and technicians are important players when it comes to Expectation #3. Why Customers tell us Fixing It Right the First Time, on Time is one of the reasons they would decide to return to a dealer to buy a vehicle and get their vehicles serviced. Technician Training It is our goal to help the technician acquire all of the skills and knowledge necessary to Fix it Right the First Time, on Time. We refer to this as competency. Technician s Role Acquire the skills and knowledge for competency in your specialty via: STST New Model Web-Based Web-Based Instructor Led Instructor Led The Benefits The successful implementation of expectations means: Satisfied customers Repeat vehicle sales Repeat service sales Recognition that Ford and Lincoln/Mercury technicians are the Best in the Business

5 MANUAL TRANSMISSION/TRANSAXLE REPAIR TABLE OF CONTENTS INTRODUCTION... INTRO - 1 Manual Transmission/Transaxle Repair... Intro - 2 Course Description...Intro - 2 Course Requirements... Intro - 3 Course Objectives...Intro - 3 Course Agenda...Intro - 3 LESSON ONE Prerequisite Review Theory and Operation Questions Diagnosis Questions LESSON ONE WORKSTATIONS Workstation 1A T5OD Disassembly Workstation 2A Disassembly and Assembly of T5OD Transmission Subassemblies Workstation 3A T5OD Transmission Assembly LESSON TWO Workstation 1B Clutch Diagnosis and Service Workstation 2B MTX-75 Transaxle Disassembly Workstation 3B MTX-75 Transaxle Assembly Manual Transmission/Transaxle Repair TOC - i August 2007

6 MANUAL TRANSMISSION/TRANSAXLE REPAIR TABLE OF CONTENTS Manual Transmission/Transaxle Repair TOC - ii August 2007

7 MANUAL TRANSMISSION/TRANSAXLE REPAIR INTRODUCTION INTRODUCTION Manual Transmission/Transaxle Repair Intro - 1 August 2007

8 MANUAL TRANSMISSION/TRANSAXLE REPAIR INTRODUCTION MANUAL TRANSMISSION/TRANSAXLE REPAIR Course Description T5OD Transmission (Left) and MTX-75 Transaxle (Right) This instructor-led course is part of the Ford Manual Transmission and Drivetrain curriculum. It is a two-day course facilitated by an instructor. This course is designed to provide hands-on opportunities for technicians to learn and improve their skills using tools and equipment, and to apply knowledge learned in prerequisite courses. Each day, you will have multiple opportunities to practice selected skills. The results of your work are recorded on worksheets. Manual Transmission/Transaxle Repair Intro - 2 August 2007

9 MANUAL TRANSMISSION/TRANSAXLE REPAIR INTRODUCTION Course Requirements Each technician attending this course is required to pass a combination of hands-on and written evaluations. These are administered after all lectures, demonstrations and/or practice sessions have been completed. The hands-on evaluation is a pass/fail type. It is conducted with exercises in manual transmission and transaxle assembly, and covers: selected end play measurements to be made during assembly service publication navigation selected special tool usage To pass the course, you must demonstrate 100% mastery of the skills covered in the Hands-On Post-Test exercises AND you must correctly answer at least 80% of the Written Post-Test questions. Course Objectives Upon successful completion of this course, you will be able to: Explain common manual transmission and transaxle system diagnostic procedures. Perform manual transmission and transaxle repairs. Perform clutch system diagnosis and service. Course Agenda Introductions Prerequisite Review WORKSTATIONS Rotation 1: T5OD Transmission Disassembly, Subassemblies and Assembly Rotation 2: Clutch Diagnosis and Service; MTX-75 Transaxle Disassembly and Assembly Workstations Review Hands-On and Written Evaluations Manual Transmission/Transaxle Repair Intro - 3 August 2007

10 MANUAL TRANSMISSION/TRANSAXLE REPAIR INTRODUCTION NOTES: Manual Transmission/Transaxle Repair Intro - 4 August 2007

11 LESSON ONE PREREQUISITE REVIEW LESSON ONE Manual Transmission/Transaxle Repair 1-1 August 2007

12 LESSON ONE PREREQUISITE REVIEW PREREQUISITE REVIEW DIRECTIONS: Answer the following questions on manual transmissions, transaxles and clutches. Questions may be related to theory, operation, diagnosis and service. These will be reviewed in class. Theory and Operation Questions 1. In a RWD manual transmission, in which direction do the following shafts rotate, relative to the engine, with the transmission moving in a forward gear? (Circle one.) Input shaft: SAME AS ENGINE ROTATION OPPOSITE TO ENGINE ROTATION Countershaft: SAME AS ENGINE ROTATION OPPOSITE TO ENGINE ROTATION Output shaft: SAME AS ENGINE ROTATION OPPOSITE TO ENGINE ROTATION 2. Number the following steps 1 through 4, to show the order of the powerflow through a RWD transmission in Reverse gear. Countershaft/gear Output shaft gear Input shaft gear Idler gear 3. List some of the reasons a synchronizer is used in a manual transmission or transaxle: Manual Transmission/Transaxle Repair 1-2 August 2007

13 LESSON ONE PREREQUISITE REVIEW 4. Dampening springs in the clutch disc or flywheel accomplish all of the following EXCEPT: A. Reduce chatter/shudder during clutch engagement B. Reduce clutch slippage C. Reduce NVH D. Absorb power pulses from the engine 5. What components in the manual transaxle differential assembly allow for wheel speed differences during cornering? Diagnosis Questions 6. A damaged shift interlock can cause which of the following concerns? (Circle all that apply.) Locked out of certain gears Two gears engaged at the same time Gear clash during shifting Transmission locked in one gear Chattering noise in forward gears Manual Transmission/Transaxle Repair 1-3 August 2007

14 LESSON ONE PREREQUISITE REVIEW 7. On a rear-wheel drive vehicle, a squealing noise is present when the clutch pedal is depressed and the vehicle is stopped with the transmission in gear. What is the likely cause? A. Clutch release bearing B. Pilot bearing C. Input shaft bearing D. Countershaft bearing 8. A whining noise is present only while driving with the manual transmission in 2 nd gear. List some components that could possibly cause this concern: 9. A whining noise is present while driving with the manual transmission in any gear except direct drive. Which of the following could cause this concern? A. Pilot bearing B. Countershaft bearings C. Input shaft bearing D. Pocket (input) thrust bearing Manual Transmission/Transaxle Repair 1-4 August 2007

15 LESSON ONE PREREQUISITE REVIEW 10. A customer complains of a grinding condition that exists whenever the T5OD manual transmission is shifted into Reverse. Technician A says that the reverse brake ring assembly could cause this concern. Technician B says that the driver may be shifting into Reverse while the vehicle is moving. Who is correct? A. Technician A B. Technician B C. Both Technicians D. Neither Technician 11. While road testing a vehicle with a manual transmission, you verify a customer concern that the transmission jumps out of gear. List the possible causes of this concern: 12. What condition could cause accelerated wear on a shift fork or synchronizer assembly? Manual Transmission/Transaxle Repair 1-5 August 2007

16 LESSON ONE PREREQUISITE REVIEW 13. What steps are required to properly test for a slipping clutch? What is the condition if the engine: stalls within 5 seconds after clutch is fully engaged? does not stall when clutch is fully engaged? 14. During removal of a manual transaxle, why is a special puller required to remove and install the halfshaft assembly from the wheel ends? 15. If a RWD transmission has worn countershaft bearings, a whining or growling noise would become quieter in which gear range? A. Reduction B. Direct drive C. Overdrive D. Reverse Manual Transmission/Transaxle Repair 1-6 August 2007

17 LESSON ONE WORKSTATIONS LESSON ONE WORKSTATIONS Workstation: 1A 2A 3A Summary: Students use the Workshop Manual and required special tools to disassemble a T5OD transmission and answer related questions in the worksheet. Students use the Workshop Manual and required special tools to disassemble and assemble selected T5OD transmission subassemblies and answer related questions in the worksheet. Students use the Workshop Manual and required special tools to assemble a T5OD transmission, perform all end play measurements, and answer related questions in the worksheet. Manual Transmission/Transaxle Repair 1-7 August 2007

18 LESSON ONE WORKSTATION 1A WORKSTATION 1A T5OD DISASSEMBLY DIRECTIONS: Complete Workstation 1A at the bench workstation, using the T5OD transmission, available hand tools and special service tools, and Workshop Manual. SUMMARY: For this activity, you will disassemble a T5OD transmission down to its major subassemblies and perform any necessary inspections required by the Workshop Manual. Follow the Mustang Workshop Manual, Section A, to disassemble the T5OD transmission to its major subassemblies. (Use the appropriate model year Workshop Manual for the transmission you have in class.) As you perform the disassembly procedures, pay attention to the following questions related to key steps. 1. Can the clutch slave cylinder retaining clip be reused? Why or why not? (Applicable to 2005 MY or newer T5OD transmissions.) 2. Upon mounting the transmission to the holding fixture, in what position must the transmission gearshift lever be placed? 3. The gearshift offset lever cannot be removed while the transmission extension housing is bolted in place. Why? 4. Why are two of the transmission cover bolts larger than the others? 5. Why is it important to NOT pry against machined sealing surfaces? 6. Why is it important to support the reverse gear shift rail with a block of wood? Follow Worksheet 2A to disassemble and assemble some of the above subassemblies. Continued on next page. Manual Transmission/Transaxle Repair 1-8 August 2007

19 LESSON ONE WORKSTATION 1A 7. Why does the Workshop Manual tell you to note the position of the reverse gearshift lever/shift fork assembly and reverse positioning spring? 8. Can the countershaft bearing retainer be reused? Why or why not? 9. What is the purpose of using tool and 205-D064 during disassembly? 10. Upon completion of the disassembly procedures in the Workshop Manual, what subassemblies are left? Manual Transmission/Transaxle Repair 1-9 August 2007

20 LESSON ONE WORKSTATION 2A WORKSTATION 2A DISASSEMBLY AND ASSEMBLY OF T5OD TRANSMISSION SUBASSEMBLIES DIRECTIONS: Complete Workstation 2A at the bench workstation, using the T5OD transmission, available hand tools and special service tools, and Workshop Manual. SUMMARY: For this activity, you will disassemble and assemble the input shaft, output shaft and one synchronizer from a T5OD transmission and perform any necessary inspections required by the Workshop Manual. Follow the Mustang Workshop Manual, Section A, to disassemble and assemble the T5OD transmission subassemblies. (Use the appropriate model year Workshop Manual for the transmission you have in class.) As you perform the disassembly and assembly procedures, pay attention to the following questions related to key steps. Input Shaft 1. Inspect the input shaft splines for wear or damage. Why is it important to do this? 2. For this activity, DO NOT remove the input shaft seal. If removed, could the input shaft seal be reused? Why or why not? 3. What condition would likely be present if the input shaft needle bearing and spacer are worn or scored? 4. Are the selective shims initially installed during assembly of the T5OD input shaft subassembly? Why or why not? Output Shaft NOTE: During disassembly, inspect bearings, needle bearings, and gears for any signs of wear or damage. 5. Be sure to remove the ball under the inner race for the 1st speed gear before removing the 1st synchronizer cones and blocking ring. What is the purpose of this ball? Continued on next page. Manual Transmission/Transaxle Repair 1-10 August 2007

21 LESSON ONE WORKSTATION 2A Synchronizer 6. Before removing a synchronizer from the output shaft, use a feeler gauge to measure the wear gap clearance between the synchronizer blocking ring and the clutching teeth on the gear. Enter the value below: If the gap is below millimeters or inches, replace the appropriate blocking ring. 7. Are synchronizer components interchangeable? Why or why not? 8. How are the springs for the synchro keys installed? 9. Why is proper clocking/timing of the synchronizer keys critical during assembly? NOTE: Assemble the synchronizer, install it on the Output Shaft and then finish assembly of the Output Shaft. Manual Transmission/Transaxle Repair 1-11 August 2007

22 LESSON ONE WORKSTATION 3A WORKSTATION 3A T5OD TRANSMISSION ASSEMBLY DIRECTIONS: Complete Workstation 3A at the bench workstation, using the T5OD transmission, available hand tools and special service tools, and Workshop Manual. SUMMARY: For this activity, you will assemble a T5OD transmission, performing any necessary measurements and inspections required by the Workshop Manual. Follow the Mustang Service Information, Section A, to assemble the T5OD transmission and perform any necessary inspections and measurements. (Use the appropriate model year Workshop Manual for the transmission you have in class.) If adjustments are required, identify the correct size select-fit part that is needed. 1. What are the instructions for soaking the blocking rings prior to assembly? 2. Use a new bearing retainer plate to obtain end play measurements. After gauging, install the original bearing retainer plate. Using the dial indicator to measure countershaft bearing gear end play. Your measurement: Specification: What size shim is needed to bring the end play within specifications? 3. When installing the reverse idler gear and bushing in the T5OD case, the shift lever groove must face toward: 4. How can you tell if the reverse positioning spring is installed correctly? 5. When installing the input shaft bearing retainer, the notch on the circular mount MUST face, and the slot must face. 6. How much silicone rubber sealant (TA-32) must be applied to the input shaft bearing retainer? 7. What would be the result if too much sealant is applied? 8. To prevent component damage, the alignment tab on the reverse brake ring must align with: 9. Using the dial indicator, measure output shaft end play. Your measurement: Specification: What size shim is needed to bring the end play within specification? Manual Transmission/Transaxle Repair 1-12 August 2007

23 LESSON TWO WORKSTATIONS LESSON TWO WORKSTATIONS Workstation: 1B 2B 3B Summary: Students use the Workshop Manual, available components and a clutch system buck to perform selected inspection, diagnosis and service tasks, including hydraulic clutch bleeding. Students use the Workshop Manual and required special tools to disassemble an MTX-75 transaxle and answer additional questions on the differential and other subassemblies. Students use the Workshop Manual and required special tools to assemble an MTX-75 transaxle and perform all end play measurements. Manual Transmission/Transaxle Repair 2-1 August 2007

24 LESSON TWO WORKSTATION 1B WORKSTATION 1B CLUTCH DIAGNOSIS AND SERVICE DIRECTIONS: For this activity, you will use components and a mock-up of the hydraulic clutch system to perform hydraulic clutch bleeding and selected clutch component inspections/tests. Refer to the 2006 Ranger Workshop Manual, Section , and complete the following worksheet questions during the activities. 1. What tests are available for the clutch pressure plate? 2. What symptoms may be present if the pressure plate adjuster is misadjusted or damaged? 3. What tests are available for the clutch disc? Refer to the 2006 Ranger Workshop Manual, Section , Pinpoint Test D. Start at Step D1 and work through this Pinpoint Test to perform: Visual Inspections Hydraulic System Internal Check Clutch Pedal Reserve Clutch Pedal Free Play Check Clutch Hydraulic System Bleeding 4. If you were performing a Clutch Pedal Reserve Check on an actual vehicle, what are some of the vehicle preparation requirements that must be done first? 5. When the above requirements have been met, how is the Clutch Pedal Reserve check performed? Continued on next page. Manual Transmission/Transaxle Repair 2-2 August 2007

25 LESSON TWO WORKSTATION 1B 6. What distance is being measured in the Clutch Pedal Free Play Check? 7. Besides opening the system for service, how else can air get into the clutch hydraulic system? 8. What conditions can be caused by air in the clutch hydraulic system? 9. What should an assistant do just before you loosen the bleeder screw to let air escape the clutch system? INSTRUCTOR DEMO: Ask your instructor to demonstrate to you how to reset an adjustable pressure plate. Refer to the 2006 Ranger Workshop Manual, Section , and answer the following questions: 10. During clutch disc and pressure plate installation, what alignment tool is required according to the Workshop Manual? 11. What is the maximum specification for tension spring adjustment when resetting the clutch pressure plate? 12. What steps must be taken to reset the pressure plate? 13. If the original clutch pressure plate or flywheel are to be reused, what are you to do? 14. What is the difference between the instructor s demonstration of the adjustable pressure plate and the adjustment procedure in the Workshop Manual? 15. What were the press target areas on the pressure plate that are critical during the Instructor Demo on the pressure plate? Manual Transmission/Transaxle Repair 2-3 August 2007

26 LESSON TWO WORKSTATION 2B WORKSTATION 2B MTX-75 TRANSAXLE DISASSEMBLY DIRECTIONS: Complete Workstation 2B at the bench workstation, using the MTX-75 transaxle, available hand tools and special service tools, and Workshop Manual. SUMMARY: For this activity, you will disassemble an MTX-75 transaxle down to its major subassemblies, performing any necessary inspections required by the 2006 Workshop Manual along the way. Follow the Focus Service Information, Section , to disassemble the MTX-75 transaxle to its major subassemblies. (Use the appropriate model year Workshop Manual for the transmission you have in class.) As you perform the disassembly procedures, pay attention to the following questions related to key steps. 1. Is the release bearing assembly reusable? Why or why not? 2. To remove the shift tower assembly, in what position must the gearshift lever be placed? 3. How are the input shaft and output shaft assemblies removed from the transaxle case? 4. What does the Workshop Manual recommend to assist in the removal of the differential, output shaft and input shaft bearing races with the slide hammer and adapter? 5. When would you need to remove the reverse idler gear shaft from the case? 6. Upon completion of the MTX-75 disassembly process, what subassemblies are left? Refer to the MTX-75 Subassembly procedures in the Workshop Manual to answer Questions 7-9. NOTE: DO NOT disassemble the Input Shaft or the Output Shaft subassemblies. 7. When servicing the input shaft and output shaft assemblies, can needle bearings and synchronizer rings be reused? 8. If removed during disassembly, can input shaft, output shaft or differential bearings be reused? Why or why not? Continued on next page. Manual Transmission/Transaxle Repair 2-4 August 2007

27 LESSON TWO WORKSTATION 2B 9. What can be replaced on the differential assembly, using the Workshop Manual? NOTE: The following questions refer ONLY to the disassembly, inspection and reassembly of the 5th/ Reverse synchronizer using the Output Shaft Subassembly section of the 2006 Focus Workshop Manual. Each student MUST disassemble and reassemble the synchronizer. Upon completion, the instructor must sign-off in the space provided below. 10. How should the output shaft bearing be removed? 11. When removing the 5th/reverse gear synchronizer assembly, what parts are to be discarded? 12. According to the Workshop Manual, why would a synchronizer need to be replaced? 13. According to the Workshop Manual, what is a recommended aid for proper synchronizer assembly? Instructor Sign-off: Manual Transmission/Transaxle Repair 2-5 August 2007

28 LESSON TWO WORKSTATION 3B WORKSTATION 3B MTX-75 TRANSAXLE ASSEMBLY DIRECTIONS: Complete Workstation 3B at the bench workstation, using the MTX-75 transaxle, available hand tools and special service tools, and Workshop Manual. SUMMARY: For this activity, you will assemble an MTX-75 transaxle, performing any necessary measurements and inspections required by the Workshop Manual. Follow the Focus Service Information, Section , to assemble the MTX-75 transaxle and perform any necessary inspections and measurements. (Use the appropriate model year Workshop Manual for the transmission you have in class.) If adjustments are required, identify the correct size select-fit part that is needed. 1. When is it necessary for you to check input shaft endplay, output shaft and differential preloads? 2. If new input shaft, output shaft and/or differential bearings are installed, what else must be done? 3. List the nominal shim sizes required when initially installing the bearings on the clutch side. Input shaft (Part No. F5RZ-7L172-DA): mm ( ) inches Output shaft (Part No. F5RZ-7N135-AA): mm ( ) inches Differential (Part No. 91ZZ-4067-XA): mm ( ) inches 4. What is the purpose of Input Shaft Socket ? 5. Using the dial indicator and the Workshop Manual procedures, measure end play/preload per the table below and calculate the shim required. Enter your answers in the appropriate spaces. MTX-75 Required Shim Thickness T ype I nput Shaft (mm) O utput Shaft (mm) Differential (mm) Measuring shims D etermined end float Preload figure End float R equired shim thickness = = = S hims available (in 0.01 mm steps) (in 0.02 mm steps) (in 0.05 mm steps) 6. How can you tell if the shift rail assemblies are installed correctly? 7. After applying sealant to the case mating surface, attaching bolts must be installed and tightened within minutes. Sealer cures rapidly. Manual Transmission/Transaxle Repair 2-6 August 2007