Ford Sierra

1982-1993 of release

Repair and operation of the car

Ford Siyerra
+ 1.2. Identification of the car
+ 2. Maintenance
+ 3. General data
+ 4. Engines
+ 5. Coupling
- 6. Transmissions
   + 6.1. Mechanical four-speed transmission
   - 6.2. Mechanical five-speed transmission
      6.2.1. Technical characteristics
      6.2.2. Removal and installation of the transmission
      6.2.3. Dismantling and assembly of the transmission
      6.2.4. Dismantling and assembly of the block of gear wheels
   + 6.3. Automatic Ford C 3 transmission
+ 7. Driveshaft and back bridge
+ 8. Steering
+ 9. Suspension brackets
+ 10. Brake system
+ 11. Body
+ 12. Electric equipment

6.2.3. Dismantling and assembly of the transmission

GENERAL INFORMATION

Case of the mechanical five-speed transmission

1 – forward part of a case,
2 – middle part of a case,
3 – back part of a case,
4 – cover,

5 – the directing plug of the release bearing of coupling,
6 – laying of a case,
7 – switch of fires of a backing

Removal of a cover of the five-speed transmission

The arrow showed an arrangement of spring locks of keeping of the included transfer.

Dismantling

PERFORMANCE ORDER

1. To remove the release bearing and forks of switching off of coupling.
2. To unscrew four bolts of fastening of a case of coupling to a forward part of a case of the transmission.
3. To take a sealing ring from a back part of a case of the transmission (adaptation 21.051).
4. To take a ring of a back part of a case of the transmission (adaptation 16.025).
Prevention This ring can be replaced only together with a back part of a case of the transmission and a secondary shaft (set).
5. To uncover a forward part of a case of the transmission.
	6. To include the 1st transfer and to beat out a pin of fastening of the selector.
	7. To take a plate, a spring and a pin of the spring lock of the 5th transfer.
8. To remove a back part of a case of the transmission.
9. To insert one bolt for preservation on the required place of a middle part of a case of the transmission.
10. To unscrew a bolt and a pin of the spring lock of an axis of the selector.
11. To take a selector axis.
12. To take knot of forks, the selector and spring locks.
	13. To take a lock ring of the synchronizer of the 5th transfer on secondary to a shaft and to move back all synchronizer.
	14. To include at the same time two transfers (for blocking of the transmission) and to unscrew a nut of fastening of a gear wheel of the 5th transfer on intermediate to a shaft.
15. By means of a core to squeeze out an axis of the block of gear wheels of an intermediate shaft back. It is necessary to keep constantly contact of a core with an axis of the block of gear wheels of an intermediate shaft not to allow loss of needles of the bearing.
16. To attach adaptation to a forward part of a case of the transmission.
	17. To remove a gear wheel of the 5th transfer from an intermediate shaft by means of adaptation 16.033
18. To insert back on the former place an axis of the block of gear wheels of an intermediate shaft, pushing out a hand adaptation 16.033 axis.
19. To remove a lock ring of the bearing of the block of gear wheels in a middle part of a case of the transmission.
20. To take the remote plug of the bearing.
21. To switch off both earlier included transfers.
22. To unscrew the bolt holding a middle part of a case of the transmission on 6 – 7 mm and to remove a middle part of a case.
	23. To press the bearing of the block of gear wheels deep into of a middle part of a case by means of two thin screw-drivers (1 and 2) and to remove an external ring of the bearing (3 – a bolt).
24. To move an axis of the block of gear wheels back so that it was possible to take the block of gear wheels from a case.
25. To lay the block of gear wheels of an intermediate shaft on a bottom of a forward part of a case of the transmission.
26. To remove the directing plug of the release bearing of coupling and to take a main shaft.
27. To take a secondary shaft together with a middle part of a case.
28. By means of the corresponding stripper (the plug of big diameter, M8Ch60 bolt together with a nut) to remove an axis of an intermediate gear wheel of the reverse gear.
29. To take a lock ring and an axis of the lever of the reverse gear.

Assembly

PERFORMANCE ORDER

1. Before assembly it is necessary to wash out and check a condition of bearings, synchronizers and gear wheels.
2. Assembly of the transmission is carried out in the return sequence in relation to process of its dismantling. In installation time it is necessary to pay attention to the following actions.
3. To grease with jellied bearing lubricant of a needle of bearings of the block of gear wheels of an intermediate shaft and it is correct to arrange them on the axis forming an internal racetrack.
	4. By means of adaptation 16.033 to establish a gear wheel of the 5th transfer on intermediate to a shaft. The remote plug from a gear wheel has to be covered with lubricant for ensuring free rotation of a gear wheel.
5. The carving of the bolts which are screwed up in through openings of a case before installation should be covered with the corresponding sealant.
6. Before tightening of a back part of a case of the transmission it is necessary to check functioning of the transmission (a possibility of inclusion of separate transfers and free rotation of shaft).