15-1025 1st 2nd Gear Jumps Out MMT6 Grbox

30.06.
2016
FordEtisTECHNICALSERVICEBULLETIN151025
No.151025
TECHNICALSERVICEBULLETIN
05March2015
2015FordMotorCompany
Allrightsreserved.
Thisbulletinrepresentstechnicalserviceinformationonly.Withoutexceptionallgratisrepairsandreplacementsaresubjecttotheindividual
warrantyandpolicyproceduresofthesupervisoryFordCompany.Theillustrations,technicalinformation,dataanddescriptivetextinthisissue,
tothebestofourknowledge,werecorrectatthetimeofpublication.
ThisbulletinsupersedesTSB62/2013.OnlyrefertotheelectronicversionofthisTSB.
Reasonforupdate:AssemblyplantSouthamptonhasbeenaddedtoTransit2006.5.
Subject/Concern:
1st/2ndgearjumpsout
Model:
Mondeo2007.5(02/200709/2014)
SMAX/Galaxy2006.5(03/200612/2014)
CMAX2010.75(07/201002/2015)
Focus2011.25(12/201004/2015)
Kuga2008.5(02/200811/2012)
Kuga2013(08/2012)
Transit2006.5(04/200604/2012)FWDonly
TransitCustom2012.75(04/2012)
Markets:
Summary
BuildDate:01.06.201112/2013
BuildCode:BYDE
AssemblyPlant:Genk
Transmission/Transaxle:6MMT6
BuildDate:01.06.201112/2013
BuildCode:BYDE
AssemblyPlant:Genk
BuildDate:01.06.201112/2013
BuildCode:BYDE
AssemblyPlant:Valencia
BuildDate:01.06.201112/2013
BuildCode:BYDE
AssemblyPlant:Saarlouis
BuildDate:01.06.201111/2012
BuildCode:BYCS
BuildDate:01.06.201112/2013
BuildCode:BYDE
BuildDate:01.10.201110/2013
BuildCode:BUDK
AssemblyPlant:Kocaeli
AssemblyPlant:Southampton
Transmission/Transaxle:6VMT6
BuildDate:01.10.201110/2013
BuildCode:BUDK
AssemblyPlant:Kocaeli
Transmission/Transaxle:6VMT6
All
Shouldacustomerexpressconcernaboutthe1st/2ndgearjumpsout,theprobablecauseiscritical
toleranceinteractionwithinthe1st/2ndgearsynchronizerassembly.
NOTE:ItisonlynecessarytodisassembleoutputshaftI,allothershaftsneedtobecheckedfor
damagesandcleanedcarefullywithoutcleaningfluid.
Torectifythisconcern,thecorrespondingtransmissionhastoberemoved,disassembledandrevised
partsfortheoutputshaftshouldbeinstalled.Thenewreleasedservicekitincludesalltherequiredlatest
levelservicepartsfortherepair.DONOTordertheindividuallypartsthatarealreadyinthekit.
FormarketswhereFordEtisIDSisused,refertoWB45/2009forthepolicyonusingFordEtis
IDSforwarrantyrepairs.IfFordEtisIDSisusedtodiagnoseacustomer'sconcern(s),select
https://www.etis.ford.com/tsb/tsbView.do?regionalNumberYear=2015&print=true&regionalNumberSequence=1025&language=en&country=NL
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theappropriatecustomersymptom(s),followanydiagnostic,repairandpostrepair
procedurespresented,andensurethecompleteddiagnosticsessionfileistransmittedto
Ford.Failuretofollowthisprocessmayaffectanyassociatedwarrantyclaimsubmission.
FormarketswhereFordEtisIDSisnotavailable,rectifythisconcernbyfollowingthe
attachedservicerepairinstruction.
Parts
FinisCode
Servicekit
1852724
seeFordEcat
seeFordEcat
seeFordEcat
seeFordEcat
seeFordEcat
seeFordEcat
Description
Quantity
Servicekit1st/2ndgearsynchronizerassemblyconsistsoff:
Screwoutputshaft
Taperrollerbearing
Snapring
Selectorfork1st/2ndgear
Synchronizerassembly1stand2ndgear
Boltbearing
Inputshaftseal
Funnel
1stgear(acc.tospecificVIN)
2ndgear(acc.tospecificVIN)
Halfshaftinnerseal
Shim
TransmissionOil(WSSM2C200D2)
FlangeSealantAnaerobicLR(WSKM2G348A5)
1
1
1
2
1
1
3
1
1
1
1
2
LaborTimes
Description
IDSVehicleConnection/Communication
Transaxle/TransmissionRemoveAndInstall
InputShaft,OutputShafts,Differential,CounterShaftRemoveAndInstall(Transmission
AssemblyRemoved)(Includes:SealsRenew)DoesNotInclude:DismantleAndAssemble
ComponentsandShimTransmission
OutputShaft(One)DismantleAndAssemble,Bearing/BearingConeRenew(InConjunction
WithOperation161183)DoesNotInclude:ShimTransmission
ShimOutputShaft(One)(InConjunctionWithOperation161183)DoesNotInclude:
DismantleAndAssembleComponents
Repair/ClaimCoding
CausalPart:
ConditionCode:
Operation
No.
290990
161140/1
161183
161504
161585
FinisCodeofthe1st/2ndgearsynchronizerassembly
33
GeneralEquipment
Twolegpuller
BrakeCleaner
Punch
HotAirGun
Tape
ServiceInstruction
SeeSummary.
Removethetransmission
1. Drainthetransmissionoil.Foradditionalinformation,refertocorrespondingWorkshopManual
Section30803.
2. Removethetransmission.Foradditionalinformation,refertocorrespondingWorkshopManual
Section30803.
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Removetheclutchslavecylinder
1. Removetheclutchslavecylinder.
Disassemblethetransmissioncase
1. Removethebracket.
2. Removethegearshiftmechanism.
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3. Useapunchtoremovetheguides.
4. Unscrewthebolts.
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5. Unscrewthebolts.
6. Removethetransmissionhousing.
Cleanthetransmissioncasewithacleancloth.
Cleanthemagnet.
Cleanthedifferentialandcheckfordamages.
Removetheinputshaftsealandthehalfshaftseals.
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7. Partiallyliftuptheshafts.
8. Removetheselectorforks.
Discardthe1st/2ndgearselectorfork.
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9. Removetheinput/outputshaftassembly.
Cleantheoutput/inputshaftandcheckfordamages.
10. Removethedifferential.
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11. Removeanddiscardthefunnel.
12. Removethehalfshaftseal.
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13. Removethebearingcone.
14. Removeanddiscardthebearingcone.
UseSpecialServiceTool:205078and20507801.
DisassembleoutputshaftI
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NOTE:ItisonlynecessarytodisassembleoutputshaftI,allothershaftsneedtobecheckedfor
damagesandcleanedcarefullywithoutcleaningfluid.
1.
CAUTION:Usevisejawprotectors.
NOTE:Allcomponentsmustbeclean.
Clamptheshaftinavise.
2. NOTE:Thecomponenthaslefthandthread.
UsetheGeneralEquipment:HotAirGun
3. Useasuitablewasherasathrustelement.
UseSpecialServiceTools:205295,308196.
4. Notethepositionofthecomponentsbeforeremoval.
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AssembleoutputshaftI
1.
CAUTION:Takeextracarewhenhandlingthecomponent.
Installanew1stgearandsinglepartsofthe1st/2ndgearsynchronizerassembly(seeParts
Required).
Material:WSSM2C200D2(TransmissionOil75WFE/7U7JM2C200BA/CA)
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2.
NOTE:Makesurethatthecomponentsareinstalledtothepositionnotedbeforeremoval.
Installsinglepartsofthe1st/2ndgearsynchronizerassembly(seePartsRequired).
3. NOTE:Makesurethatthecomponentsareinstalledtothepositionnotedbeforeremoval.
Installanew2ndgearandsinglepartsofthe1st/2ndgearsynchronizerassembly(seeParts
Required).
1.Installanewsnapring(seePartsRequired).
2.Material:WSSM2C200D2(TransmissionOil75WFE/7U7JM2C200BA/CA)
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4. NOTE:Makesurethatthecomponentsareinstalledtothepositionnotedbeforeremoval.
Assembletheoutputshaft.
Material:WSSM2C200D2(TransmissionOil75WFE/7U7JM2C200BA/CA)
5.
NOTE:Makesurethatthecomponentsareinstalledtothepositionnotedbeforeremoval.
Assembletheoutputshaft.
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6. NOTE:Makesurethatanewcomponentisinstalled.
Installanewsnapring(seePartRequired).
1.Snapring
2.Material:WSSM2C200D2(TransmissionOil75WFE/7U7JM2C200BA/CA)
7.
CAUTION:Donotdamagethelowerbearingretainer.Useasuitablethrustto
supporttheshaftduringinstallation.
NOTE:Makesurethatanewcomponentisinstalled.Therollerbearingmustnotbelubricated.
UseSpecialServiceTool:20415801,308046andanhydraulicpresstoinstallanewbearing
(seePartsRequired).
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8. NOTE:Makesurethatanewboltisinstalled.Thecomponenthasalefthandthread.
NOTE:Makesurethatthecomponentiscleanandfreeofforeignmaterial.
Installanewscrewoutputshaft(seePartsRequired).
Torque.100Nm
9. Installthehalfshaftseal.
10. Installthebearingcone.
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Calculatetherequiredshimthickness
1. Makesurethatthecomponentiscleanandfreeofforeignmaterial.
2. NOTE:Extremecleanlinessmustbeexercisedwhenhandlingthecomponents.Rollerbearings
mustnotbelubricated.
Installtheoutputshaft.
1.Takeextracarenottodamagethebearing.
2.Bearingcone.
3.UseSpecialtool308603
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3. Repeattheadjustmentprocedurethreetimesandcalculatetheaverageofthevalues.
4. Holdthebearingouterracesandpressthespecialtooldownatthesametime.
5. Installspecialtool206003.
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6. Installspecialtools205070and307430.
7. Tightenthebolts.
Torque:32Nm
8. Unscrewtheboltsandcarefullyremovethetransmissionhousing.
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9. Usespecialtools30730002,30730003,308603.
Toavoidmeasurementerrors,onlypresslightlyonthespecialtoolwhenusingthedepth
gauge.
Recordthemeasurementresults.
10. Calculatetherequiredshimthicknessonthe1st4thgearoutputshaft.
Addthemeasuredvalues,dividebythreeandthenaddthebearingpreloadvalue.
Bearingpreload:0.17mm
Example:1.56mm+1.57mm+1.55mmdividedbythree=1.56mm.1.56mm+0.17mm=
1.73mm.
Ifthethicknessofthemeasuredshimisodd,selecttheshimwiththenexthigherthickness
value.
Determinedadjustingshimthickness:1.74mm.
11. Removespecialtools205070,206003and307430.
12. Removethefollowingitems:
1.Specialtool308603
2.Bearingcone
3.Outputshaft
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Assemblethetransmission
1. Installthefollowingitems(seePartsRequired).
1.Useahotairgun
2.Funnel
3.Adjustingshim(ascalculatedpreviously)(seePartsRequired).
4.Installtheremovedbearingcone.
2. Usespecialtools:205073and308605.
3. Installthedifferential.
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4. Installtheinput/outputshaftassembly.
5. Installtheselectorforks.
Installanewselectorfork1st/2ndgear(seePartsRequired).
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6.
CAUTION:Takeextracarenottodamagethematingfaces.Makesurethatthe
componentisclean,freeofforeignmaterialandlubricant.
Cleanallmatingfacesusingbrakecleaner.
7. Applysealer(seePartsRequired).
Material:FlangeSealantAnaerobicLR(WSKM2G348A5)
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8. Installthetransmissionhousing.
Installthemagnet.
9. Assemblethetransmissionhousing.
1.Onlytightentheboltsfingertightatthisstage.
NOTE:Installnewbolts(seePartsRequired).
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10. Useapunchtoinstalltheguide.
11. Tightenthebolts.
1.Torque:6SpeedManualTransmissionVMT6:40Nm6SpeedManualTransmissionMMT6:
32Nm
2.Torque:6SpeedManualTransmissionVMT6:40Nm6SpeedManualTransmissionMMT6:
32Nm
3.Torque:30Nm
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12. Tightenthebolts.
Torque:40Nm
13.
Makesurethatallselectorforksareinneutralposition.
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14.
Applysealer(seePartsRequired).
Material:FlangeSealantAnaerobicLR(WSKM2G348A5)
15. Installthegearshiftmechanism.
1.Makesurethatthegearshiftmechanismisinneutralposition.
2.Installnewbolts(seePartsRequired).Torque:26Nm
16. Installthebracket.
Torque:15Nm
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17. NOTE:ManualTransmissionVMT6only.
Installanewinputshaftseal(seePartsRequired).
1.Useadhesivetapetocovertheinputshaftsplinestopreventdamagetotheinputshaftseal.
2.Inputshaftseal
3.SpecialTool307032A.
4.Removetheequipment.
18. NOTE:ManualTransmissionMMT6only.
Installanewinputshaftseal(seePartsRequired).
Useadhesivetapetocovertheinputshaftsplinestopreventdamagetotheinputshaftseal.
1.Inputshaftseal
2.SpecialTool308112.
Removetheequipment.
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19. Installtheclutchslavecylinder.
1.Torque:11Nm
20. Installnewhalfshaftsealsonbothsides(seePartsRequired).Foradditionalinformation,referto
correspondingWorkshopManualSection30803.
21. Installthetransmission.Foradditionalinformation,refertocorrespondingWorkshopManual
Section30803.
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15-1025 1st 2nd Gear Jumps Out MMT6 Grbox

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