Ford Focus 2012 2013 WSM Pages Deleted Pages Deleted

308-03B
Manual Transmission - Vehicles With: 6-Speed Manual Transmission - MMT6 2012 - 2013 Focus
Description and Operation Procedure revision date:
07/26/2012
Manual Transmission - Overview
Overview
The MMT6 manual transmission features the following:
Two-part aluminum housing

All gear wheels are helical toothed and are constantly engaged
1st, 2nd, 3rd and 4th gear are triple synchronized.
5th, 6th and reverse gear have double synchronization
By optimizing the friction in the transmission and using a lower viscosity transmission fluid, it has been possible to achieve
fuel savings and thereby reduce CO2 emissions. Information on the specification can be found in FordEtis
An externally mounted gearshift mechanism
All driving gears of the transmission are located on the input shaft
The input shaft is designed as a solid shaft and runs on one ball bearing and one roller bearing with no pre-load
The gears for 1st and 2nd gear are an integral part of the input shaft. The gears for 3rd and 5th gears and the gear for
4th/6th
gear are pressed on. Because of the high force used to press on the components, the gears cannot be pressed off in
service.
A faulty input shaft can only be replaced as a complete unit
Defective bearings can be pressed off and changed
The output pinion of the 1st/4th gear output shaft is an integral part of the shaft
The synchronizers of the 1st/2nd and the 3rd/4th gears are located on the output shaft
The 1st/4th gear output shaft is a hollow shaft. The fluid is directed into the inner diameter of the hollow shaft for lubrication
of the needle bearings and the synchronizer units. Both output shafts run on taper roller bearings which are pre-loaded with
the aid of adjusting shims in the clutch housing
The output pinion is an integral part of the shaft
The 5th/6th and reverse gear synchronizer assemblies are located on the shaft
The 5th/6th/reverse gear output shaft is a hollow shaft. The fluid is directed into the inner diameter of the hollow shaft
for
lubrication of the needle bearings and the synchronizer units. Both output shafts run on taper roller bearings which are
pre-
loaded with the aid of adjusting shims in the clutch housing
The differential runs on taper roller bearings and is pre-loaded with the aid of an adjusting shim in the clutch housing
Location of components
Overview of external components

Item Description
1 Vent assembly
2 Gearshift mechanism
3 Reverse gear switch
Overview of inner components
Item Description
1 Differential
2 Reverse gear idler
3 Selector fork - reverse gear
4 5th gear idler
5 5th/6th gear selector fork
6 6th gear idler
7 5th/6th/Reverse Gear Output Shaft
8 Selector rod - 5th/6th/reverse gear
9 Input shaft
10 1st - 4th gear output shaft
11 4th/6th gear fixed
12 Selector rod - 1st/4th gear
13 Selector fork - 3rd/4th gear
14 3rd gear fixed
15 5th gear fixed
16 Selector fork - 1st/2nd gear
17 1st gear fixed
Input shaft
Item Description
1 Input shaft
2 Input shaft bearing
3 1st gear
4 2nd gear
5 5th gear
6 3rd gear
7 4th/6th gear
8 Input shaft ball bearing
9 Bearing retaining bolt
Output shaft 1st/4th gear
Item Description
1 Clutch housing taper roller bearing
2 1st/4th gear
3 1st gear and reverse gear idler gear
4 1st/2nd gear sliding collar
5 1st/2nd gear synchroniszer hub
6 2nd gear
7 3rd gear
8 3rd/4th gear synchronizer hub
9 3rd/4th gear sliding collar
10 Snap ring
11 1st/2nd gear synchronizer
12 Stop disc unit
13 3rd/4th gear synchronizer
14 4th gear
15 Transmission housing taper roller bearing
16 Bearing retaining bolt (left-hand thread)
5th/6th/Reverse Gear Output Shaft
Item Description
2 5th/6th/reverse gear output gear
3 Reverse gear
4 Reverse gear sliding sleeve
5 Reverse gear synchronizer hub
6 Snap ring
7 5th/6th gear synchronizer hub
8 Reverse gear synchronizer
9 Stop disc unit
10 5th gear
11 5th/6th gear sliding collar
12 5th/6th gear synchronizer
13 6th gear
14 Taper roller bearing, transmission housing
15 Bearing retaining bolt (left-hand thread)
Differential
Item Description
1 Shim
3 Differential
4 Ring gear bolts
5 Transmission housing taper roller bearing
6 Ring gear
Copyright © Ford Motor Company

308-03B Manual Transmission - Vehicles With: 6-Speed Manual Transmission - MMT6 2012 - 2013 Focus
07/26/2012
Manual Transmission - System Operation and Component Description
System Diagram
Power transmission route in 1st gear
Power transmission route in 2nd gear
Power transmission route in 3rd gear

Power transmission route in 4th gear

Power transmission route in reverse gear
System Operation
Power transmission route in 1st gear
The 1st gear is positively connected to the 1st to 4th gear output shaft by the 1st/2nd gear synchronizer assembly.
Power transmission route in 2nd gear
The 2nd gear is positively connected to the 1st to 4th gear output shaft by the 1st/2nd gear synchronizer assembly.
Power transmission route in 3rd gear
The 3rd gear is positively connected to the 1st to 4th gear output shaft by the 3rd/4th gear synchronizer assembly.
The 4th gear is positively connected to the 1st to 4th gear output shaft by the 3rd/4th gear synchronizer assembly.
The 5th gear is positively connected to the 5th/6th/reverse gear output shaft by the 5th/6th gear synchronizer assembly.
The 6th gear is positively connected to the 5th/6th/reverse gear output shaft by the 5th/6th gear synchronizer assembly.
Power transmission route in reverse gear

The reverse gear idler is welded to the 1st gear. It is constantly engaged with the reverse gear wheel.
The reverse gear wheel is positively connected to the 5th/6th/reverse gear output shaft by the reverse gear synchronizer assembly.
Component Description
Synchronizers
Synchroniser ring for triple synchronisation in 1st/2nd gear
Item Description
1 Inner synchronizer ring with friction material on the inside
2 Synchronizer cone with friction material on the inside and outside
3 Outer synchronizer ring
Synchronizer rings for 3rd/4th gear double synchronization
Item Description
1 Inner synchronizer ring with friction material on the outside
2 Synchronizer cone
3 Outer synchronizer ring with friction material on the inside
Synchronizer rings for single synchronization in 5th/6th/reverse gear
Item Description
1 Synchronizer ring
2 Synchronizer cone
Internal gearshift mechanism
Item Description
1 Shift arm with integrated shift weight
2 Selector arm
3 Reverse gear switch
4 Gear shift mechanism housing
5 Vent assembly
6 Selector finger
7 Selector shaft
The internal shift mechanism contains the shift gate, a counter balance and reverse gear switch. The reverse gear switch can
be
serviced. The counter balance and shift gate can only be changed as a complete unit in service.
The shift gate is built into the gear shift mechanism housing.
The reverse gear switch is located on the housing cover of the internal shift mechanism.
The counterbalance built into the shift arm improves the smoothness of the gear shifting. The inertia of the shift weight
(counterbalance) reduces the tangible shift resistances of the synchronization during gearshifts. The gearshift process becomes
smoother.

Removal and Installation Procedure revision date:
07/29/2012
Halfshaft Seal RH
Removal
1. WARNING: Before beginning any service procedure in this section, refer to Safety Warnings in section 100-00
General Information. Failure
to follow this instruction may result in serious personal injury.
Refer to: Health and Safety Precautions

(100-00 General Information, Description and Operation).
Refer to: Jacking and Lifting - Overview

(100-02 Jacking and Lifting, Description and Operation).
2.
1. If equipped.
3.
4.
5. NOTICE: Do not use a prying device or separator fork between the ball joint and the wheel knuckle. Damage to the
ball joint or ball
joint seal may result. Only use the pry bar by inserting it into the lower arm body opening.
NOTICE: Use care when releasing the lower arm and wheel knuckle into the resting position or damage to the ball
joint seal may occur.
6.
7.
Installation
1. NOTE: Make sure new component is installed.
Special Tool(s)
: 205-115 Installer, Drive Pinion Seal
2. NOTE: Do not fully install the halfshaft at this time.
3. NOTE: Insert the intermediate shaft until the intermediate shaft bearing is centered in the concave groove of the
intermediate shaft
bearing bracket.
Connect the following items:

1.
2. Torque
: 5 Nm
3. Torque
: 5 Nm
4. Torque
: 25 Nm
5. Torque
: 25 Nm
4.
5.
6.
7. Refer to: Transmission Fluid Level Check

(308-03B Manual Transmission - Vehicles With: 6-Speed Manual Transmission -
MMT6, General Procedures).
8. Torque
: 10 Nm
9.
2. If equipped.

07/26/2012
Halfshaft Seal LH
Removal
1. Refer to: Health and Safety Precautions


2.
1. If equipped.
3. Remove the LH
halfshaft.
Refer to: Front Halfshaft LH
(205-04 Front Drive Halfshafts, Removal and Installation).
4.
Installation
1. Special Tool(s)
2. Install the LH
halfshaft.

Refer to: Transmission Fluid Level Check

3.
2. If equipped.
4. Lower the Vehicle.

07/27/2012
Selector Mechanism
Removal
WARNING: Before beginning any service procedure in this section, refer to Safety Warnings in section 100-00 General
Information. Failure

Refer to: Battery Disconnect and Connect

(414-01 Battery, Mounting and Cables, General Procedures).
2.
3.
4.
5. Set the manual shift lever in the neutral (N) position.
6. Set the manual shift lever in the neutral (N) position.
7.
1. Set the manual shift lever in the neutral (N) position. Turn the component CW through 90 degrees.
2. NOTE: Make sure that no components catch.

Installation
1. Material
: Gasket Maker
/ TA-16
(WSK-M2G348-A5)
2.
Set the manual shift lever to the neutral (N) position. Visual check.
3.
1. Set the manual shift lever to the neutral (N) position. Turn the componenet CCW through 90 degrees.
4. Torque
: 26 Nm
5. Refer to: Gearshift Cable Adjustment - Vehicles With: 6-Speed Manual Transmission - MMT6
(308-06 Manual Transmission
External Controls, General Procedures).
6. Torque
: 24 Nm
7.
8. Refer to: Battery Disconnect and Connect
(414-01 Battery, Mounting and Cables, General Procedures).

07/29/2012
Input Shaft Seal
Removal
1. WARNING: Before beginning any service procedure in this section, refer to Safety Warnings in section 100-00
General Information. Failure
Refer to: Health and Safety Precautions

2. Refer to: Transmission - 2.0L EcoBoost (184kW/250PS) - MI4

(308-03B Manual Transmission - Vehicles With: 6-Speed
Manual Transmission - MMT6, Removal).
3.
4. NOTICE: Take extra care not to damage the bearing.
5.
1. 2.5 x 15 mm self-tapping screw. Screwdriver. Turn the component CW through 2 complete turns.
2. Combination pliers.
Installation
1.
1. NOTICE: Use adhesive tape to cover the input shaft splines to prevent damage to the input shaft seal.
Apply tape to specified component or area.

General Equipment
: Adhesive Tape
2. NOTE: Make sure that a new component is installed.
3. Special Tool(s)
: 308-112 Installer, Output Drive Flange Seal
4. Discard the specified component. Follow local disposal regulations.
2. Torque
: 11 Nm

308-03A Manual Transmission - Vehicles With: 5-Speed Manual Transmission - MTX75 2012 - 2013 Focus
Specifications Procedure revision date:
07/28/2012
Specifications

Capacities
Liters
Transmission fluid (0- 5 mm below the lower edge of the inspection hole) 1.9

Transmission ratios
2.0L engine
1st gear 3.667
2nd gear 2.136
3rd gear 1.448
4th gear 1.028
5th gear 0.805
Reverse gear 3.727
Final drive 3.824

Shim thickness required
Description Input shaft Output shaft Differential assembly

Measuring shims (mm) 1.00 1.00 1.10
Measured end float (example) (mm) + 0.22 + 0.32 + 0.36
Preload figure (mm) – + 0.13 + 0.33
End float (mm) – 0.07 – –
Required shim thickness (example) = 1.15 = 1.45 = 1.79
(mm)
Shims available (mm) 1.15 – 1.71 (in steps of 0.01 1.31 – 1.91 (in steps of 0,02 1.40 – 2.20 (in steps of 0.05
mm) mm) mm)
07/26/2012
Halfshaft Seal LH
Removal


2.
1. If equipped.
3. Refer to: Front Halfshaft LH

4. Special Tool(s)
: 308-208 Remover, Halfshaft Seal
Installation
1. Special Tool(s)

(308-03A Manual Transmission - Vehicles With: 5-Speed Manual Transmission -
MTX75, General Procedures).
3.
2. If equipped.

07/26/2012
Halfshaft Seal RH
Removal


2.
1. If equipped.
3. Refer to: Front Halfshaft RH

4. Special Tool(s)
Installation
1. Special Tool(s)
2. Refer to: Front Halfshaft RH

3.
2. If equipped.

07/26/2012
Selector Mechanism
Removal

2. Refer to: Jacking and Lifting - Overview

3.
1. If equipped.
2. If equipped.
5. Install the following items:

General Equipment
: Trolley Jack
General Equipment
: Wooden Block
6. Refer to: Air Cleaner

(303-12A Intake Air Distribution and Filtering - 2.0L Duratec-HE (125kW/170PS) - MI4, Removal and
Installation).
Refer to: Battery Tray

(414-01 Battery, Mounting and Cables, Removal and Installation).
7.
8.
9.
10.
11.
12. NOTICE: Make sure that the wiring harness does not catch.
Installation
1.
2. NOTE: Make sure that the mating faces are clean and free of foreign material.
Material
: Gasket Maker
/ TA-16
(WSK-M2G348-A5)
4. NOTE: Note the different lengths of the bolts.
1. Torque
: 26 Nm
2. Torque
: 26 Nm
5. Torque
: 80 Nm
6.
7. WARNING: Make sure that a new bolt is installed.
Torque
: 148 Nm
8. Refer to: Gearshift Cable Adjustment - Vehicles With: 5-Speed Manual Transmission - MTX75
9. Torque
: 48 Nm
10. Refer to: Battery Tray

Refer to: Battery

Refer to: Air Cleaner

Installation).
11. Remove the following items:

General Equipment
: Wooden Block
General Equipment
: Trolley Jack

13.
1. If equipped.
2. If equipped.

07/26/2012
3rd-4th Gear Synchronizer
Removal

2.
1. Install Special Service Tool
: 205-329 Mounting Bracket, Engine/Differential
, 303-435 Mounting Stand
, 303-435-
06 Mounting Bracket for 303-435
3. Set the manual shift lever to the neutral (N) position.
5. WARNING: Be prepared to collect escaping fluid.
Special Tool(s)
Special Tool(s)
5.
6.
7. NOTE: Note the position of the components before removal.
8.
9.
General Equipment
: Vise Jaw Protectors
NOTICE: Use vise jaw protectors.

1. Roller bearing. Discard the specified component. Follow local disposal regulations.
Special Tool(s)
: 205-295 Remover, Bearing (Main Tool)
, 308-195 Collet for 205-295
12. Special Tool(s)

: 308-230 Support Plate, Gear Removal (Dia 85.1 mm)
General Equipment
: Hydraulic Press
14.
Disassemble the following items:

1.
2.
3.
4.
5.
Installation
NOTICE: Use vise jaws protectors.
1. NOTE: Make sure that the components are installed to the position noted before removal.
Lubricate the synchronizer rings with manual transmission fluid before assembly.
Material
: Motorcraft® Dual Clutch Transmission Fluid
/ XT-11-QDC
(WSS-M2C200-D2)
2. Assemble the following items:

1.
2.
3.
3.

5. Special Tool(s)
: 205-068 Installer, Drive Pinion Bearing
General Equipment
: Hydraulic Press
2. Special Tool(s)
: 308-044 Installer, Transmission Extension Housing Bushing/Seal
8. Keep the reverse gear idler shaft bearing block raised while installing the shaft.
Special Tool(s)
: 308-214 Remover, Hydraulic Line Spring Clip
10. Material
/ XT-11-QDC
(WSS-M2C200-D2)
11.
1. Install the input and output shafts together.
2. Move the input and output shafts to one side.
3. Remove Special Service Tool

Install the following items:

1.
2.
3.

1. Material
: Gasket Maker
/ TA-16
(WSK-M2G348-A5)
Torque
: 34 Nm
2.
3.
4.
14. Material
: Gasket Maker
/ TA-16
(WSK-M2G348-A5)
15. NOTICE: The guide pins must remain installed in the gearbox housing.
16. Tighten the bolts in a crisscross sequence.
Torque
: 40 Nm
Special Tool(s)
Material
: Gasket Maker
/ TA-16
(WSK-M2G348-A5)
Special Tool(s)
2. NOTICE: Use adhesive tape to cover the input shaft splines to prevent damage to the input shaft seal.
NOTE: Make sure that a new component is installed.
3. NOTE: Make sure that new components are installed.
Torque
: 11 Nm
20. Remove the adhesive tape from the input shaft splines.
21.
22. Material
: Gasket Maker
/ TA-16
(WSK-M2G348-A5)
23.
Torque
: 26 Nm
3. Torque
: 26 Nm
4. Torque
: 40 Nm
, 303-435-06 Mounting Bracket for
303-435
Disassembly Procedure revision date:
07/26/2012
Transmission
1.
, 303-435-
06 Mounting Bracket for 303-435
2. Items to be removed.
4. NOTE: Marking the components makes installation easier.
5. Items to be removed.
2. Special Tool(s)
3. Special Tool(s)
4.
5.

7.
8.
10. Special Tool(s)

: 205-176 Remover, Differential Bearing Cone
11. Special Tool(s)
: 205-078 Remover, Drive Pinion Seal
, 205-078-01 Adapter for 205-078 (Thrust Pad)
12. Special Tool(s)

13. Special Tool(s)

14. The following two steps should only be performed if the reverse gear idler shaft is damaged.
15.
16.

Disassembly and Assembly of Subassemblies Procedure revision date:
07/26/2012
Output Shaft
DISASSEMBLY
1. Clamp the output shaft in a vise.
2. Only remove the bearing if it is to be renewed.
General Equipment
: Puller
3. Special Tool(s)
: 205-310 Remover, Bearing/Gear
General Equipment
: Hydraulic Press
4. Discard the snap ring.
5. NOTICE: The detent balls are spring-loaded. Take care when removing the selector ring from the synchronizer hub.
NOTE: Note the position of each component before removal.

1. Selector ring
2. Synchronizer body
3. Compression springs
4. Blocker bars
5. Detent balls
7. Special Tool(s)
: 205-310 Remover, Bearing/Gear
General Equipment
: Hydraulic Press
8. Hot air gun. The allowable temperature range for the specified task
General Equipment
: Hydraulic Press
General Equipment
: Puller

1. Selector ring
4. Blocker bars
5. Detent balls
11.
ASSEMBLY
1. Clamp the output shaft in a vise.
2. Lubricate the synchronizer rings with manual transmission fluid before assembly.
Material
/ XT-11-QDC
(WSS-M2C200-D2)
3.

2. Blocker bars and detent balls
3. Selector ring
5. WARNING: Only use moderate force
Install a new snap ring.
6. Special Tool(s)
: 308-605 Installer, Input Shaft Seal
General Equipment
: Hydraulic Press
7.
1. Special Tool(s)
: 308-605 Installer, Input Shaft Seal
General Equipment
: Hydraulic Press
2. Install a new snap ring.

3. Selector ring
10. The roller bearing must not be lubricated.
Special Tool(s)
Special Tool(s)
07/26/2012
Input Shaft
DISASSEMBLY
1. Clamp the input shaft in a vise.
2. Special Tool(s)
, 308-196 Collet for 205-295

1. Roller bearing
Special Tool(s)
, 308-195 Collet for 205-295
4. Special Tool(s)
: 308-230 Support Plate, Gear Removal (Dia 85.1 mm)
General Equipment
: Hydraulic Press
6.

1. Selector ring
4. Blocker bars
5. Detent balls
ASSEMBLY
1. Clamp the input shaft in a vise.
2. Lubricate the synchronizer rings with manual transmission fluid before assembly.
Material
/ XT-11-QDC
(WSS-M2C200-D2)

3. Selector ring
4.
6. Special Tool(s)
: 205-068 Installer, Drive Pinion Bearing
General Equipment
: Hydraulic Press

Special Tool(s)
Special Tool(s)
07/26/2012
Differential
DISASSEMBLY
1. Clamp the differential in a vise.
2. Special Tool(s)
: 205-071-01 Adapter for 205-071 (Thrust Pad)
, 205-295 Remover, Bearing (Main Tool)
, 308-197 Collet for
205-295
3. Special Tool(s)
: 205-071-01 Adapter for 205-071 (Thrust Pad)
, 205-295 Remover, Bearing (Main Tool)
, 308-197 Collet for
205-295

1. Loosen
: Four turn(s)
2. Discard the specified componenet. Follow local disposal regulations.
3. Save three bolts for reassembly the ring gear.
5. Hammer. Discard the specified componenet. Follow local disposal regulations.

ASSEMBLY
1. Clamp the differential in a vise.
2. Carefully clean and check all parts and coat with manual transmission fluid before assembly.
Material
/ XT-11-QDC
(WSS-M2C200-D2)
3. Install the three bolts saved during disassembly.
Torque
: 83 Nm
4. Discard the specified componenet. Follow local disposal regulations.
5. NOTICE: Make sure that new bolts are installed.
Torque
: 83 Nm
Special Tool(s)
: 205-081 Installer, Differential Bearing
Special Tool(s)
: 205-081 Installer, Differential Bearing

308-06 Manual Transmission External Controls 2012 - 2013 Focus
07/17/2012
Gearshift Lever - Vehicles With: 6-Speed Manual Transmission - B6/6-Speed Manual Transmission - MMT6
Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Floor Console - Vehicles With: Center Armrest

(501-12 Instrument Panel and Console, Removal and Installation).
Refer to: Floor Console - Vehicles Without: Center Armrest

(501-12 Instrument Panel and Console, Removal and
Installation).
2. Torque
: 9 Nm
3.
Installation
1. To install, reverse the removal procedure.
2. Adjust the selector lever cable when a new selector lever is installed.
Refer to: Gearshift Cable Adjustment - Vehicles With: 6-Speed Manual Transmission - MMT6 (308-00 Manual Transmission
and Clutch - General Information)
.

07/17/2012
Gearshift Lever - Vehicles With: 5-Speed Manual Transmission - B5/IB5/5-Speed Manual Transmission - MTX75
Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Floor Console - Vehicles With: Center Armrest

(501-12 Instrument Panel and Console, Removal and Installation).
Refer to: Floor Console - Vehicles Without: Center Armrest

(501-12 Instrument Panel and Console, Removal and
Installation).
2. Torque
: 9 Nm
3.
Installation
1. To install, reverse the removal procedure.
2. Adjust the selector lever cable when a new selector lever is installed.
Refer to: Gearshift Cable Adjustment - Vehicles With: 5-Speed Manual Transmission - MTX75 (308-00 Manual Transmission
.

01/24/2013
Gearshift Cables - Vehicles With: 6-Speed Manual Transmission - MMT6
Removal

2.

4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Installation
1. Torque
: 9 Nm
2.
3.
4.
5.
1. Torque
: 10 Nm
2. Torque
: 25 Nm
6.
7.
8.
9.
10.
12. Refer to: Gearshift Cable Adjustment - Vehicles With: 6-Speed Manual Transmission - MMT6 (308-00 Manual Transmission
.

01/24/2013
Gearshift Cables - Vehicles With: 5-Speed Manual Transmission - MTX75
Removal
1. Refer to: Air Cleaner Outlet Pipe

(303-12A Intake Air Distribution and Filtering - 2.0L Duratec-HE (125kW/170PS) - MI4,
Removal and Installation).
2.

4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Installation
1. Torque
: 9 Nm
2.
3.
4.
5.
Torque
: 10 Nm
Torque
: 25 Nm
6.
7.
8.
9.
10.
11.
12. Refer to: Air Cleaner Outlet Pipe
(303-12A Intake Air Distribution and Filtering - 2.0L Duratec-HE (125kW/170PS) - MI4,
Removal and Installation).
13. Refer to: Gearshift Cable Adjustment - Vehicles With: 5-Speed Manual Transmission - MTX75 (308-00 Manual Transmission
.

Removal Procedure revision date:
02/4/2013
Transmission - 2.0L EcoBoost (184kW/250PS) - MI4
1.

3.
4.
5.
6.
7.
8.

10. If equipped.
11.
12.
13.
3. If equipped.
14.
15.
2. Loosen
: 2 turn(s)
16.
17. Remove the LH

fender splash shield.
Refer to: Fender Splash Shield

(501-02 Front End Body Panels, Removal and Installation).

19. Refer to: Wheel and Tire

(204-04A Wheels and Tires, Removal and Installation).
20. NOTICE: Do not use a prying device or separator fork between the ball joint and the wheel knuckle. Damage to the
ball joint or ball
joint seal may result. Only use the pry bar by inserting it into the lower arm body opening.
NOTICE: Use care when releasing the lower arm and wheel knuckle into the resting position or damage to the ball
joint seal may occur.
21. WARNING: Be prepared to collect escaping fluid.
22.
1. Using part: 97ZT-7M181-A Seal Protector.
23. NOTICE: The inner constant velocity (CV) joint must not be bent more than 18°.
NOTICE: The outer constant velocity (CV) joint must not be bent more than 45°.
24.
25.
26. Refer to: Cowl Panel Grille

27. Special Tool(s)

: 303-F072 Support Bar, Engine
28.
29.
30. NOTICE: Make sure that all openings are sealed.

32. General Equipment

: Wooden Block
General Equipment
: Retaining Strap
General Equipment
: Transmission Jack
33.
34.
35.
Installation Procedure revision date:
02/4/2013
Transmission - 2.0L EcoBoost (184kW/250PS) - MI4
1. Material
: Grease - High Temperature
(ESD-M1C220-A)
2.
3. Tighten on both sides simultaneously.

Torque
: 48 Nm
General Equipment
: Wooden Block
General Equipment
: Retaining Strap
General Equipment
: Transmission Jack

6. Torque
: 80 Nm

Torque
: 148 Nm
8. Remove special tool.
Special Tool(s)
9.

11. Torque
: 48 Nm
12. Torque
: 48 Nm

14. Refer to: Fender Splash Shield

15. NOTE: Do not fully install the halfshaft at this time.
Using part: 97ZT-7M181-A Seal Protector.
16.
Torque
: 6 Nm

Torque
: 6 Nm
4. Torque
: 25 Nm
5. Torque
: 25 Nm
17. Torque
: 83 Nm
18. Torque
: 10 Nm
19. Refer to: Wheel and Tire

(204-04A Wheels and Tires, Removal and Installation).
20.
1. Torque
: 85 Nm
2. Torque
: 48 Nm
21.
1. Torque
:
Stage 1:
30 Nm
Stage 2:
270°
2. Torque
: 85 Nm
22. Torque
: 25 Nm
23.
1. If equipped.
24.
1. Torque
: 25 Nm
2. Torque
: 24 Nm
25.
1. Torque
: 10 Nm
2. Torque
: 5 Nm
27. Torque
: 40 Nm
28. Torque
: 25 Nm
29. Torque
: 48 Nm
30. Torque
: 25 Nm
31.
32. Refer to: Gearshift Cables - Vehicles With: 6-Speed Manual Transmission - MMT6
(308-06 Manual Transmission External
Controls, Removal and Installation).
33. Torque
: 48 Nm
35. Refer to: Battery

36. Refer to: Air Cleaner

(303-12B Intake Air Distribution and Filtering - 2.0L EcoBoost (184kW/250PS) - MI4, Removal and
Installation).
37. Refer to: Cowl Panel Grille

38. Refer to: Windshield Wiper Pivot Arm

(501-16 Wipers and Washers, Removal and Installation).

40. If equipped.
41. Refer to: Clutch System Bleeding (308-00 Manual Transmission and Clutch - General Information)
.
42.
07/26/2012
Manual Transmission - Overview
Componenet Location
Item Service Part Number Description

1 7017 Input shaft
2 7061 Output shaft
3 7141 Reverse gear idler
4 7112 4th gear
5 7124 3rd and 4th gear synchronizer
6 7B340 3rd gear
7 - Output drive pinion
8 7100 1st gear
9 7124 1st and 2nd gear synchronizer
10 7102 2nd gear
11 7K316 5th gear
12 7124 5th and reverse gear synchronizer
13 7141 Reverse gear
Overview
The MTX-75 manual transmission features the following:
Two-part aluminum housing

The input shaft has 2 tapered roller bearings. Input shaft end play is controlled by a selective shim located under the bearing
cup
The output shaft has 2 tapered roller bearings. Output shaft end play is controlled by a selective shim located under the
bearing cup
The differential has 2 tapered roller bearings. Differential end play is controlled by a selective shim located under the
bearing
cup
All gears are bevel cut
All gears, including reverse, turn on needle bearings
Synchronized in all gears
1st and 2nd gear are dual synchronized
Single piece brass shift forks
The input shaft, output shaft and the differential assembly are assembled under preload. If the transmission is disassembled,
a
preload measurement must be taken.
The transmission's function is to move the vehicle from a rest position to motion. This is done by transferring the engine
torque,
through the transaxle, to the vehicle's front wheels. The transmission uses gears to adapt the torque to the demands
of load and
road conditions. It matches engine power to vehicle needs.
This power is delivered from the engine's flywheel, to the transaxle. The power is transmitted through a driver-operated clutch,
which allows for engagement and disengagement of the engine to the transaxle.

07/26/2012
Manual Transmission - System Operation and Component Description
System Operation
Neutral
In NEUTRAL there is no powerflow through the transmission. The vehicle will stay stationary.
1st Gear
The input shaft drives the output shaft.

The 1st gear on the input shaft drives 1st gear on the output shaft.
The 1st/2nd gear synchronizer is splined to the output shaft.
When the 1-2 synchronizer sleeve is shifted forward, 1st gear is locked to the output shaft.
The output shaft drives the differential ring gear.
The power flows through the side and pinion gears to the halfshafts.
2nd Gear

The 2nd gear on the input shaft drives 2nd gear on the output shaft.
The 1st/2nd gear synchronizer is splined to the output shaft.
When the 1-2 synchronizer sleeve is shifted rearward, 2nd gear is locked to the output shaft.
3rd Gear

The 3rd gear on the input shaft drives 3rd gear on the output shaft.
The 3rd/4th gear synchronizer is splined to the input shaft.
When the 3-4 synchronizer sleeve is shifted forward, 3rd gear is locked to the input shaft.
4th Gear

The 4th gear on the input shaft drives 4th gear on the output shaft.
The 3rd/4th gear synchronizer is splined to the input shaft.
When the 3-4 synchronizer sleeve is shifted rearward, 4th gear is locked to the input shaft.
5th Gear

The 5th gear on the input shaft drives 5th gear on the output shaft.
The 5th/reverse gear synchronizer is splined to the output shaft.
When the 5th/reverse gear synchronizer sleeve is shifted forward, 5th gear is locked to the output shaft.
Reverse
The input shaft drives the reverse idler gear.

The reverse gear on the input shaft drives reverse gear on the output shaft.
The reverse gear synchronizer is splined to the output shaft.
When the reverse gear synchronizer sleeve is shifted rearward, reverse gear is locked to the output shaft. The reverse idler
gear drives reverse gear on the input shaft, in a reverse direction.
Component Description
Selector Mechanism
The selector mechanism is the link between the transmission shift cables and the transmission.
It is externally mounted on the transmission and consists of levers and rods which control the shift forks inside the transmission.
The shift and selector cables connect to levers on the outside.
The selector mechanism is replaced as an assembly.
Input Shaft
The input shaft is the main shaft splined to the clutch disc and turns the gears in the transmission.
The gears on the input shaft mesh with the output shaft gears and provide torque from the engine to the differential.
The input shaft has two tapered roller bearings. Input shaft end play is controlled by a selective shim located under the
bearing cup.
Output Shaft
The output shaft transfers torque to the ring gear, pinion gears, and differential.
The output shaft has a gear for each drive gear, including reverse. 1st, 2nd, 5th and reverse gears are free to spin around
the
output shaft. 3rd and 4th gears are free to spin on the input shaft. The synchronizers engage the gears locking them to
the output
shaft.
The output shaft has two tapered roller bearings. Output shaft end play is controlled by a selective shim located under the
bearing
cup.
Differential
The ends of the differential are supported on tapered roller differential bearings. The cups for these differential bearings
are seated
in the transmission case and the flywheel housing. Differential bearing preload is set using a selective differential
bearing shim that
is installed under the differential bearing cup in the transmission case.
The differential includes the differential side gears and the shaft mounted differential pinion gears. Direct contact between
the gears
and the differential case is prevented by the differential side gear thrust washers installed under the gears. The
differential pinion
shaft is held in position by a differential pinion shaft lock pin that extends through the end of the
differential pinion shaft and the
differential case.
The differential has two tapered roller bearings. Differential end play is controlled by a selective shim located under the
bearing cup.
Synchronizer
The synchronizers are designed to act as the torque carrying interfaces between each speed gear and corresponding output shaft.
The synchronizer design and function are similar to manual transmission operations.
Gear pre-selection is made by sliding the synchronizer sleeve towards a speed gear. This causes the internal splines of the
synchronizer sleeve to bridge a gap between the output hub and the external spline feature of the speed gear, thus transmitting
speed and torque between the gear and output shaft. Synchronizers are small cone wet friction clutches mounted to the
transmission
output shaft and input shaft. They are used to bring the rotation speed of the engaging speed gear in sync with the
output
shaft speed. After synchronous speed has been attained the final power flow connection is made possible and the
synchronizer
sleeve is permitted to pass by and engage the external spline teeth on the speed gear.

Removal Procedure revision date:
07/26/2012
Transmission


Installation).
Refer to: Battery Tray

2.
3.
4.
5.

7.
1. If equipped.
2. If equipped.
8.
9.
10. Drain the transmission fluid.
Torque
: 35 Nm

12. If equipped.
13.
14.
15.
16.
17.
18. Special Tool(s)

: 205-775 Protector, Halfshaft Seal
19.
20.
21.
22.
24. Support the engine.
Special Tool(s)
25.
26.
27. NOTICE: Make sure that all openings are sealed.


General Equipment
: Transmission Jack
General Equipment
: Wooden Block
General Equipment
: Retaining Strap
30.
31.
32.

Assembly Procedure revision date:
07/26/2012
Transmission
1.
1. Material
: Gasket Maker
/ TA-16
(WSK-M2G348-A5)
2. Fit the temporary bolt.
2.
1. Remove the temporary bolt.
2. NOTE: Make sure that new bolts are installed.
Torque
: 24 Nm
3.
: Hot Air Gun
2. Insert bearing outer rings manually.
4. Special Tool(s)
: 204-050 Installer, Front Wheel Hub Bearing Cup/Seal
, 205-075 Installer, Rear Wheel Hub Seal
, 307-
210 Installer, Input Shaft Seal
5.
: Hot Air Gun
2. Install a 1.10 mm measuring shim.
3. Install 1.00 mm measuring shims.
6. Special Tool(s)
: 204-017 Installer, Wheel Hub Bearing Cup
, 204-050 Installer, Front Wheel Hub Bearing Cup/Seal
, 205-
075 Installer, Rear Wheel Hub Seal
7.
8. NOTE: Do not oil the taper roller bearing.

1.
2.
3.
NOTE: The mounting faces of the component must be clean and free from foreign bodies and lubricant.
Tighten the bolts in a crisscross sequence.
Torque
: 40 Nm
10. Special Tool(s)

: 308-194B Holding Fixture, Dial Indicator Gauge (Output Shaft End Play)

: 205-069 Dial Indicator Gauge (Metric)
, 205-070 Holding Fixture, Dial Indicator Gauge
, 307-
300 Gauge Bar, Shim Selection
12. Input shaft measurement: Perform the following two steps three times and calculate the average of the measurements.
(Example:
(0.22 mm + 0.23 mm + 0.21 mm) / 3 = 0.22 mm)
13. Special Tool(s)

: 205-175 Socket, Drive Pinion Nut
14.
1. Pre-load the dial gauge to 1 mm and zero it.
2. Lift the input shaft with a suitable lever and note the resulting measurement.
15. Output shaft measurement: Perform the following three steps three times and calculate the average of the measurements.
(Example:
(0.32 mm + 0.33 mm + 0.31 mm) / 3 = 0.32 mm)
16. Special Tool(s)

17. Attach the dial gauge, pre-load it to 1 mm and zero it.
Special Tool(s)
18. Lift the output shaft with a suitable lever and note the resulting measurement.

: 303-060 Compressor, Valve Spring
, 303-060-02 Adapter for 303-060
, 303-060-07 Adapter for
303-060
20. Differential measurement: Perform the following two steps three times and calculate the average of the measurements.
(Example:
(0.34 mm + 0.36 mm + 0.38 mm) / 3 = 0.36 mm)
21.
1. Press down the differential during rotation.
Special Tool(s)
2. Pre-load the dial gauge to 1 mm and zero it.
Special Tool(s)
22. Lift the differential with the special tool and note the resulting measurement.
Special Tool(s)
: 303-060 Compressor, Valve Spring
, 303-060-02 Adapter for 303-060
23.
Calculate the required adjusting shim thickness for the input shaft:
Installed measuring shim thickness: 1.00 mm.
Calculated average input shaft end float e. g. 0.22 mm.
End float constant: -0.07 mm.
Shim thickness required: 1.00 mm +0.22 mm -0.07 mm = 1.15 mm
24.
Calculate the required adjusting shim thickness for the output shaft:
Installed measurement shim thickness: 1.00 mm.
Calculated average output shaft end float, e.g.: 0.32 mm.
Pre-load constant 0.13 mm.
Shim thickness required: 1.00 mm +0.32 mm +0.13 mm = 1.45 mm.
25.
Calculate the required adjusting shim thickness for the differential:
Installed measurement shim thickness: 1.10 mm.
Calculated average differential end float e. g. 0.36 mm.
Pre-load constant 0.33 mm.
Shim thickness required: 1.10 mm + 0.36 mm +0.33 mm = 1.79 mm.

, 205-070 Holding Fixture, Dial Indicator Gauge
, 303-
060 Compressor, Valve Spring
, 303-060-02 Adapter for 303-060
, 303-060-07 Adapter for 303-060
, 307-300 Gauge Bar,
Shim Selection
, 308-194B Holding Fixture, Dial Indicator Gauge (Output Shaft End Play)
27.
28.
29. Special Tool(s)

30. Special Tool(s)
31.
: Hot Air Gun
2. Install the measured adjusting shim.
32. Special Tool(s)

: 204-017 Installer, Wheel Hub Bearing Cup
, 204-050 Installer, Front Wheel Hub Bearing Cup/Seal
, 205-
075 Installer, Rear Wheel Hub Seal
33. NOTE: Make sure that these components are installed to the noted removal position.
34. Keep the reverse gear idler shaft bearing block raised while installing the shaft.
Special Tool(s)
35.
36. Material
/ XT-11-QDC
(WSS-M2C200-D2)
37.
1. Install the input and output shafts together.
2. Move the input and output shafts to one side.

38. NOTE: Make sure that these components are installed to the noted removal position.

1.
2.
3.

1. Material
: Gasket Maker
/ TA-16
(WSK-M2G348-A5)
Torque
: 34 Nm
2.
3.
4.
40. Material
: Gasket Maker
/ TA-16
(WSK-M2G348-A5)
42. Tighten the bolts in a crisscross sequence.
Torque
: 40 Nm
43.
If the starting torque is too high, all the measurements must be repeated.
Engage fourth gear.
Special Tool(s)
: 205-067 Preload Gauge
, 205-175 Socket, Drive Pinion Nut
Starting torque 1 Nm.
44. Special Tool(s)

Material
: Gasket Maker
/ TA-16
(WSK-M2G348-A5)
1. Special Tool(s)
2. NOTICE: Cover the input shaft splines with adhesive tape to avoid damaging the input shaft oil seal.
NOTE: Make sure that a new component is installed.
3. NOTE: Make sure that new bolts are installed.
Torque
: 11 Nm
47. Remove the adhesive tape from the input shaft splines.
48.
49. Material
: Gasket Maker
/ TA-16
(WSK-M2G348-A5)
50.
1.
2. Torque
: 26 Nm
3. Torque
: 26 Nm
4. Torque
: 40 Nm
, 303-435-06 Mounting Bracket for
303-435

Installation Procedure revision date:
07/26/2012
Transmission

2. Apply a thin coating.
Material
: High Temperature 4x4 Front Axle and Wheel Bearing Grease
/ XG-11
(WSS-M1C267-A1)
3.
4. Tighten on both sides simultaneously.
Torque
: 48 Nm
General Equipment
: Transmission Jack
General Equipment
: Wooden Block
General Equipment
: Retaining Strap
7. Refer to: Clutch System Bleeding (308-00 Manual Transmission and Clutch - General Information)
.
8. Torque
: 80 Nm
9.
Torque
: 148 Nm


13. Torque
: 48 Nm
14. Torque
: 48 Nm
15.
1. Torque
: 48 Nm
2. Torque
:
Stage 1:
30 Nm
Stage 2:
270°
16.
18. NOTE: Remove the special tool before completely installing the halfshaft.
Special Tool(s)
: 205-775 Protector, Halfshaft Seal
Torque
: 6 Nm
Torque
: 6 Nm
4. Torque
: 25 Nm
5. Torque
: 25 Nm
20.
21.
22. Torque
: 83 Nm

1. Torque
: 35 Nm
2. Torque
: 10 Nm
25. Torque
: 25 Nm
26.
1. If equipped.
2. If equipped.
28. Torque
: 48 Nm
29.
30. Refer to: Gearshift Cable Adjustment - Vehicles With: 5-Speed Manual Transmission - MTX75
31.
32. Torque
: 48 Nm
Refer to: Battery


Installation).

308-01 Clutch 2012 - 2013 Focus
08/1/2012
Clutch Disc and Pressure Plate - Vehicles With: 5-Speed Manual Transmission - MTX75
Removal
1. Refer to: Transmission

(308-03A Manual Transmission - Vehicles With: 5-Speed Manual Transmission - MTX75, Removal).
2. Loosen each bolt 2 turns at a time until all bolts are removed.
Installation
1. Special Tool(s): Universal clutch alignment tool.
2. Tighten each bolt 2 turns at a time.
Torque
: 29 Nm
3. Refer to: Transmission

(308-03A Manual Transmission - Vehicles With: 5-Speed Manual Transmission - MTX75,
Installation).

308-01 Clutch 2012 - 2013 Focus
07/26/2012
Clutch - Overview
Components of a clutch
Item Description
1 Flywheel
2 Clutch disc with friction lining
3 Cover assembly
A Sectional plane A
The clutch consists of:
Flywheel
Clutch disc
Cover assembly
When the clutch pedal is depressed, the clutch slave cylinder moves the release bearing which presses the center of the diaphragm
spring on to the compression ring towards the flywheel. The diaphragm spring fingers rest on diaphragm spring rings and lift
the
compression ring from the clutch disc. The compression spring is relieved, allowing the flow of force to the transmission
to be
interrupted for gear-changing.
If the clutch pedal is not depressed, force flows to the transmission due to the compressive force of the diaphragm spring
on the
compression ring.
Self-adjusting clutches
The clutch size has also been increased with the introduction of more powerful engines. The self-adjusting clutch eliminates
the
increase in operating force which occurs as wear increases.
The advantages of the self-adjusting clutch are as follows:
Constant operating force throughout the whole service life of the clutch.
Increased service life of the clutch friction disc.
Shorter release bearing travel.
Self-adjusting clutches cannot be reset after the clutch friction disk has been renewed and must also be renewed.

308-01 Clutch 2012 - 2013 Focus
07/26/2012
Clutch - System Operation and Component Description
System Operation
How the clutch works
Cross-sectional view of a single-disc dry clutch
Item Description
A Clutch disengaged
B Clutch engaged
1 Flywheel
2 Clutch disc with friction lining
3 Pressing ring
4 Diaphragm spring
5 Transmission input shaft
6 Clutch cover
7 Crankshaft Dimensions
The clutch transmits the torque from the engine to the transaxle; when the clutch pedal is depressed the power transmission
from
the engine to the transaxle is interrupted.
When the clutch pedal is not depressed the clutch is engaged. Pressing down the pedal disengages the clutch.
A dry clutch usually only has one clutch disc, the coatings of which are specially designed for dry friction with a higher
coefficient of
friction. The torque which can be transmitted also depends on the size and number of friction surfaces and
the pressing force.
The flywheel and pressing ring are connected to the crankshaft in a rotationally fixed way and transmit the torque via the
friction
linings of the clutch disc to the input shaft of the transaxle. The clutch disc is clamped between the flywheel and
the pressing ring.
The force from the diaphragm spring provides the necessary contact pressure.
The clutch cover, pressing ring and diaphragm spring are also referred to jointly as the cover assembly
.
The wear on the clutch disc is greatest at the pressure point during engagement of the clutch. If the pressing ring is moved
away
from the flywheel then there is no longer any friction to the clutch disc, and the connection is disengaged.
The most frequent damage observed on the clutch is too low friction (sliding) between the clutch disc and the pressing ring
or
flywheel. This can be caused by oil leaks, friction lining wear or a weakening diaphragm spring.

308-02 Clutch Controls 2012 - 2013 Focus
07/26/2012
Clutch Controls - Overview
Componenet Location

Item Description
1 Clutch slave cylinder bolts
2 Clutch slave cylinder
3 Slave cylinder hydraulic tube
4 Lower clutch hydraulic tube
5 Clutch master cylinder

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308-03B

Manual Transmission - Overview

The MMT6 manual transmission features the following:

Two-part aluminum housing

Overview of external components

Overview of inner components

Output shaft 1st/4th gear

5th/6th/Reverse Gear Output Shaft

Copyright © Ford Motor Company

Manual Transmission - System Operation and Component Description

Power transmission route in 1st gear

Power transmission route in 2nd gear

Power transmission route in 3rd gear

Power transmission route in 4th gear

Power transmission route in 5th gear

Power transmission route in 6th gear

Power transmission route in reverse gear

Power transmission route in 1st gear

Power transmission route in 2nd gear

Power transmission route in 3rd gear

Power transmission route in 4th gear

Power transmission route in 5th gear

Power transmission route in 6th gear

Power transmission route in reverse gear

Synchroniser ring for triple synchronisation in 1st/2nd gear

Synchronizer rings for 3rd/4th gear double synchronization

Internal gearshift mechanism

Copyright © Ford Motor Company

Refer to: Health and Safety Precautions

Refer to: Jacking and Lifting - Overview

1. NOTE: Make sure new component is installed.

2. NOTE: Do not fully install the halfshaft at this time.

Connect the following items:

7. Refer to: Transmission Fluid Level Check

Copyright © Ford Motor Company

1. Refer to: Health and Safety Precautions

Refer to: Jacking and Lifting - Overview

Refer to: Front Halfshaft LH

Refer to: Transmission Fluid Level Check

4. Lower the Vehicle.

Copyright © Ford Motor Company

1. Refer to: Health and Safety Precautions

Refer to: Battery Disconnect and Connect

5. Set the manual shift lever in the neutral (N) position.

6. Set the manual shift lever in the neutral (N) position.

2. NOTE: Make sure that no components catch.

1. NOTE: Make sure that no components catch.

2. NOTE: Make sure that no components catch.

Copyright © Ford Motor Company

Input Shaft Seal

Refer to: Health and Safety Precautions

2. Refer to: Transmission - 2.0L EcoBoost (184kW/250PS) - MI4

4. NOTICE: Take extra care not to damage the bearing.

Apply tape to specified component or area.

2. NOTE: Make sure that a new component is installed.

Copyright © Ford Motor Company

Description Input shaft Output shaft Differential assembly

1. Refer to: Health and Safety Precautions

Refer to: Jacking and Lifting - Overview

3. Refer to: Front Halfshaft LH

Refer to: Transmission Fluid Level Check

4. Lower the Vehicle.

Copyright © Ford Motor Company

1. Refer to: Health and Safety Precautions