DIY ford transit gearbox repair

In detail: do-it-yourself repair of a Ford transit checkpoint from a real master for the site my.housecope.com.

On the territory of the Russian Federation (delivery in Moscow), the publishing house's products can be purchased in the online store of the largest book-selling company "Avtoinform96"

Manual transmission MT -75

1. Clutch driven shaft / Output shaft. 2. Front side of the case. 3. Third / fourth gear shift fork. 4. Gear shift fork. 5. Back side of the case. 6. Drive output flange. 7. Reverse gear. 8. Speedometer shaft Ford Transit.

The MT-75 is a three-shaft gearbox.

The abbreviation means the following:

- 75: distance between output shaft and speedometer shaft in mm.

The aluminum gearbox housing consists of two closed sections. Stiffening ribs in the transmission housing are provided to reduce noise and vibration.

A three-shaft transmission assumes that all gears are in simultaneous engagement.

When reverse gear is engaged, the direction of rotation of the output shaft is changed by the idler gear.

The input and output shafts rotate on tapered roller bearings.

All gears, including the reverse gear, have a tapered tooth profile, are synchronized and rotate on needle roller bearings.

Driven shaft and speedometer shaft

1. Input shaft. 2. Shift fork for third / fourth gear. 3. Fifth / reverse gear selector fork. 4. Output shaft. 5. Reverse gear. 6. Speedometer shaft.

1. Input shaft. 2. The driving gear of the speedometer shaft. 3. Teeth of the synchronizer of the fourth gear. 4. Thrust bearing of the output shaft.

Video (click to play).

Output shaft (left view shown)

1. Output shaft. 2. Needle roller bearing. 3. Cogwheel of the first transfer. 4. First gear synchronizer ring. 5. First / second gear synchronizer sleeve. 6. Second gear synchronizer ring. 7. Retaining ring. 8. Needle roller bearing. 9. Gear wheel of the second transfer. 10. Inner race of third gear needle roller bearing. 11. Needle roller bearing. 12. Cogwheel of the third transfer. 13. Ring of the synchronizer of the third gear. 14. Synchronizer clutch for third / fourth gear. 15. Ring of the synchronizer of the fourth gear. 16. Retaining ring.

Output shaft (right side view shown)

1. Output shaft. 2. Needle roller bearing. 3. Reverse gear. 4. Reverse gear synchronizer ring. 5. First / reverse gear synchronizer clutch. 6. First gear synchronizer ring. 7. Retaining ring. 8. Needle roller bearing. 9. Cogwheel of the first transfer.

1. Inner ring of the bearing. 2. Intermediate shaft.

Reverse idler gear

1. Fastening the reverse idler gear shaft. 2. Cylindrical pin. 3. Reverse idler gear. 4. Needle roller bearing. 5. Shaft of the intermediate gear wheel of reverse gear.

Main bridge Ford Transit in a block with a VXT-75 gearbox

1. Reversing mechanism assembly. 2. Transmission housing. 3. Clutch housing. 4. Single synchronizer. 5 Dual synchronizer. 6. Clutch slave cylinder. 7. Input shaft. 8. Distance between the center line of the input shaft and the center line of the output shaft. 9. Output shaft. 10. Differential. 11. Gear wheels of the third and fourth gears.

Drive shaft (vehicles built before 08/2001):

1. Drive shaft. 2. Gear wheel of the second transfer. 3. Gear wheel of the first transfer. 4. Tapered roller bearing. 5. Roller bearing of the third gear. 6. Gear wheel of the third transfer. 7.Third gear synchronizer cone. 8. Third gear synchronizer ring. 9. Synchronizer clutch for third and fourth gears. 10. Retaining ring. 11. Ring of the synchronizer of the fourth gear. 12. Fourth gear needle roller bearing. 13. Gear wheel of the fourth transfer. 14. Gear wheel of the fifth transfer. 15. Retaining ring. 16. Tapered roller bearing.

Drive shaft (vehicles built after 08/2001):

1. Drive shaft. 2. Gear wheel of the second transfer. 3. Gear wheel of the first transfer. 4. Tapered roller bearing. 5. Roller bearing of the third gear. 6. Gear wheel of the third transfer. 7. Third gear synchronizer ring. 8. Synchronizer clutch for third and fourth gears. 9. Retaining ring. 10. Ring of the synchronizer of the fourth gear. 11. Fourth gear needle roller bearing. 12. Gear wheel of the fourth transfer. 13. Gear wheel of the fifth transfer. 14. Retaining ring. 15. Tapered roller bearing.

1. Tapered roller bearing. 2. Drive gear of the output shaft. 3. Output shaft. 4. First gear needle roller bearing. 5. Gear wheel of the first transfer. 6. Inner ring of the first gear synchronizer. 7. First gear synchronizer cone. 8. Outer ring of the first gear synchronizer. 9. Synchronizer clutch of the first and second gears assembled. 10. Retaining ring. 11. Second gear synchronizer ring. 12. Second gear synchronizer cone. 13. Inner ring of the second gear synchronizer. 14. Gear wheel of the second transfer. 15. Second gear needle roller bearing. 16. Gear wheel of the third transfer. 17. Gear wheel of the fourth transfer. 18. Retaining ring. 19. First gear needle roller bearing. 20. Gear wheel of the first transfer. 21. Ring of the synchronizer of the first transfer. 22. Synchronizer clutch of the first and reverse gears, assy. 23. Retaining ring. 24. Reverse gear synchronizer ring. 25. Reverse gear needle roller bearing. 26. Reverse gear. 27. Tapered roller bearing.

1. An adjusting washer. 2. Roller bearing. 3. Ring of the vehicle speed sensor. 4. Carter (cup) differential. 5. Crown gear.

Removal and transmission installation

Manual transmission MT -75

1. Disconnect the negative plug of the storage battery.

2. Remove the shift lever extension.

1) Pull on the protective cover.

2) Tighten the stopper and remove the shift lever extension.

3) Remove the insulating material.

3. Remove the gear lever insulating material.

4. Remove the gear shift lever.

5. Raise and secure the vehicle.

6. Loosen the drive shaft front intermediate bearing retaining bolts.

Cars Ford Transit issued before 10/2001:

Mark the position of the drive shaft flange in relation to the gearbox output flange.

7. Disconnect the drive shaft from the gearbox output flange and move to one side.

Cars built after 10/2001:

Mark the position of the drive shaft flange in relation to the gearbox output flange.

8. Disconnect the drive shaft from the gearbox output flange and move to one side.

9. Disconnect the steering column resilient coupling from the steering gear.

1) Unscrew the lower clamping screw.

2) Remove the steering column shaft and move to the side.

Cars with additional heater:

10. Disconnect the power steering pipe from the front axle cross member.

11. When using a two-post lift: unscrew the bolts securing the elastic mounts of the gearbox to the cross member of the front axle.

12. If using a four post lift, support the engine on a block of wood.

13. Using a suitable transmission jack, support the vehicle underneath the cross member.

14.Using a suitable transmission jack, support the front axle cross member.

15. Lower the front axle cross member 150 mm (illustration shows left side view).

- Loosen the four bolts ten turns.

16. Turn the clutch slave cylinder counterclockwise, disconnect the clutch slave cylinder from the gearbox Ford Transit.

Cars equipped with a tachograph:

On vehicles manufactured before 10/2001, the gearbox output shaft flange has four bolts. On vehicles built after 10/2001, the gearbox output flange has three bolts.

17. Disconnect the tachograph sensor electrical connector.

18. Disconnect the reversing light and vehicle speed sensor electrical connectors.

19. Remove the heat shield and disconnect the crankshaft position sensor.

20. Disconnect the starter ground wire.

21. Disconnect the starter from the transmission.

22. Unscrew one bolt securing the transmission on the right side and one on the left side.

23. Install the M10 x 60 mm fixing pins.

24. Unscrew the remaining transmission mounting bolts on the left side.

25. Unscrew the remaining bolts securing the transmission on the right side.

Move the transmission back enough to provide access to the bolts of the elastic support of the transmission.

26. Remove the transmission resilient support.

Do not tilt the transmission during removal. This can damage the pilot bearing.

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4 Jul 2016 Most of the refurbishment or repair work has to be done only after removing the Ford Transit gearbox. The only question is how to dismantle and install such a massive unit? What points to consider when implementing such a task?

To remove the gearbox on a Ford Transit, follow the steps below:

Discard the "minus" from the battery (vehicle power source);

Pull the handbrake, jack the front of the car and fix the vehicle on the supports. At the same time, make sure that the established gap is sufficient for carrying out repair work;

Prepare an empty container and place it under the drain hole. After completing the work, reinstall the plug;

On machines equipped with independent suspension, it is recommended to lower the front suspension beam to ensure sufficient clearance. To accomplish this task, first dismantle the coil-type spring springs, then substitute the jack under the cross-type beam and raise the jack until it takes over the weight of the product. Remove a pair of bolts on each side holding the cross member to the body. Then release the beam by unscrewing the jack about 10 cm;

On engines with an air filter mounted on the intake manifold, dismantle the air filter itself;

Dismantle the gearbox selector and starter;

If they are installed, then release the connectors and dismantle the lower motor cover, consisting of two elements and covering the clutch housing;

Disconnect the muffler intake pipe from the manifold. On cars of the last years of production, to improve access, it is recommended to disconnect the front flange of the intake pipe and dismantle the intake pipe itself;

Separate the release fork rubber shroud from the clutch housing, then slide the inner cable out of the slot on the release fork. Then release the cable sheath from the clutch housing.Remove the rubber boot from the cable;

Throw away the cable connector that supplies the reversing lamp, then take the cable aside;

Unscrew the fastening bolt, dismantle the fastening plate of the speedometer drive cable, then remove the cable from the gearbox and remove it to the side;

If an electronic tachograph is mounted on the Ford Transit, discard the assembly wiring and lay it aside;

Unscrew the group of bolts and remove the clutch from the crankcase;

Place a jack under the checkpoint to support the weight of the device;

Unscrew the fixing bolt in the center or a pair of nuts holding the “box” fasteners to the crankcase. Then unscrew a couple of bolts on each side and dismantle the transverse beam;

Remove the retaining bolts that hold the motor and clutch housing together (including the single bolts that hold the motor brackets). Note that on some models one of the bolts secures the support bracket or motor ground strip. In this case, a pair of bolts from above hold the fuel line fastener;

Support the engine sump with a second jack or blocks while the Ford Transit is completely removed. Next, use a jack to install a flat block between the pallet and the head of the lifting device;

Make sure again that all components are pushed away from and away from the transmission. With the help of a repair partner, tilt the box slightly backwards and then throw the product away from the motor. Make sure that the box does not rest on the drive shaft with all its weight. If necessary, dismantle the clutch housing with the engine dowel pin;

Throw away the box, lower it and reach through the bottom of the car.

After completing repair work, the Ford Transit manual transmission is installed in place. Here the sequence is as follows:

Install in the reverse order of dismantling. Before connecting the manual transmission to the engine, make sure that the clutch release bearing is installed correctly, and then apply a small amount of lubricant to the gearbox drive shaft. If the clutch was replaced during work, then it should be centered in such a way that the gearbox drive shaft can go into the slots of the clutch system driven disc, as well as into the crankshaft bearing;

Once the box is connected to the motor, install a pair of fixing bolts and refit the crosspiece. In a situation where the MT75 box is installed on the Ford Transit, then check that the red dot on the cross is directed to the front of the car. After that, stretch all the bolts to the desired moment;

When installing the clutch cable, follow the instructions in the instruction manual. Also, be careful when installing the starter, propeller shaft, speed selector and air filter. If the coil springs were dismantled, then they must also be installed in the reverse order of dismantling;

The last stage of the work is to fill the gearbox with oil. Pay special attention to the type of lubricant - it must meet the requirements of the car manufacturer. Otherwise, there is a risk of reducing the resource of an expensive unit or its premature failure of one of the elements.

Repair of the gearbox in the case of dismantling the unit requires not only special training, but also knowledge of certain nuances of the work. A violation of technology or the absence of a certain tool can nullify the possibility of repairing equipment or lead to even more serious consequences.

Please contact us for service. The specialists of our service station have been dealing with Ford cars for a long time, they know their features and nuances of repair.A responsible approach to work guarantees the result in the form of a serviceable gearbox and its high-quality operation for a long time.

Ford manufactures vehicles that are highly reliable, and some of their units deserve a positive assessment. A Ford manual transmission, for example, is not very demanding to maintain. An automatic transmission, in comparison with a mechanic, is the most complex and high-tech element of a car. So Ford Transit gearbox repair must be carried out by qualified specialists, but first it is necessary to diagnose the unit using special diagnostic equipment.

Although the FordTransit gearbox has proven itself well on domestic roads and once again does not bother the driver, from time to time diagnostics and repair of this element of the car are necessary. This is done in order to once again make sure that it works and to prevent problems in the future. Of course, you shouldn't delay with diagnostics. To postpone the trip to the specialists, as they say later, means to expose the gearbox to greater danger. How much easier and cheaper it is to solve problems in advance than to resort to expensive capital repairs of the unit in the future.

Oil leakage. This is usually due to worn or damaged oil seals, gaskets, or loose crankcase cover fasteners. To eliminate these malfunctions, it is enough to replace the failed parts and tighten the crankcase cover fasteners;
Noises during gearbox operation. Most often they occur due to wear on bearings, splines, gears, or a faulty synchronizer. Eliminated by replacing worn parts;
Difficulty shifting gears. This occurs due to the breakdown of parts of the gearshift mechanism, wear of gears and synchronizers. Eliminated in the same way as described above;
Self-switching off of gears (knocking out speed). In most cases, this is due to a faulty locking device and, in addition, due to severe wear of synchronizers and gears. It is eliminated by replacing the blocking device and failed synchronizers and transmission gears.

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The repair of a manual transmission, as well as the repair of an automatic transmission, is quite often caused by the extreme behavior of the driver while driving a car and, besides this, a banal non-observance of the rules for operating this unit. For example, an untimely oil change. But sometimes there are cases that the car owner pours a completely different oil into this unit, which is recommended by the manufacturer. In this case, no one will give a guarantee for long-term operation and perfect operation of the gearbox.

Often times, breakdowns and malfunctions in a FordTransit transmission are caused by a rude attitude towards the gear lever. For example, if the owner of the car constantly "pulls" the lever, namely, switches the speed with sharp, quick movements, then the day is not far away when he will have to pay a tidy sum not only for the repair of the gearbox, but also for the repair of the car. If the shift lever is handled in this way, the result of such treatment will be the failure of the synchronizers and the shift mechanism. In addition, do not forget that the gears and shafts are "iron" for the time being.

The gears of the car should be engaged in a smooth movement at all times, making micro-pauses in neutral. This is done so that the synchronizers have time to work, the task of which is to protect the gears from failure.

While operating the car, and with it the FordTransit gearbox, you must constantly monitor the oil level and, if necessary, top up.A complete oil change is recommended to be carried out within the timeframes specified by the company in the "Operating Instructions" of the car.

Image - DIY Ford Transit checkpoint repair

To ensure a high level of quality in maintenance and repair, use of original spare parts and consumables is required.

Gearbox repair mechanical type is a complex process, which cannot be successfully performed on its own. During repairs, special attention is paid to mechanical wear of parts and parts, which can be caused by:

natural wear and tear;
improper operation of nodes;
lack of lubricants.

Successful manual transmission repair directly depends on the successful diagnosis of the causes of its failure, and will eliminate all negative factors of the occurrence of defects.

Repair of manual transmission Ford Transit should be performed every time any extraneous sounds are detected, inadequate gear shifting or other signs indicating deviations from the normal operation of the transmission. The main causes of extraneous noise at the checkpoint can be:

high degree of bearing wear;
wear of synchronizers;
the presence of backlash on the shaft;
production of gears;
low oil level or poor quality.

Timely operative intervention in the unstable operation of the gearbox allows you to prevent larger breakdowns and emergency breakdowns. The main guarantee of the flawless operation of the manual transmission throughout the entire period of operation is the performance of scheduled maintenance and inspection. The implementation of all measures allows you to achieve stable operation of the transmission for the entire period of its operation.

The main technical measures that are carried out during the periodic maintenance of the gearbox are checking the oil level and monitoring the presence of its leaks. If a leak is detected, it must be eliminated immediately. After that, check the oil level, for which perform the following steps:

the car is installed on a flat area;
unscrew the plug of the control filling hole;
visually or using a special dipstick, the oil level is checked.

The main reasons for a decrease in the oil level in the gearbox can be:

shaft seal defects;
weak attachment of the crankcase cover;
subsidence of gaskets;
poor fastening at the junction of the crankcase and box.

If there is a shortage of oil, its balance should be replenished by topping up through the control filling hole. On a 5-speed gearbox, wait for the oil to drain into the fifth gear housing and then check the level again. You should be aware that on type G boxes the plug is located on the right side of the crankcase, and on MT75 and N boxes on the left side. After completing all control and measuring procedures and replenishing the oil level, screw the plug back in with some tightening.

Changing the oil in the gearbox of a Ford Transit is not part of the standard routine maintenance list. But, with its unsatisfactory quality, it is imperative to replace it. To do this, perform the following operations in sequence:

install a container under the drain plug, which should then be unscrewed;
after the entire volume of oil has flowed out, install the plug in place;
There is no drain plug on the N gearbox and the oil can be changed by removing the gearbox from the vehicle.

Capital gearbox repair it is practically impossible to carry out without dismantling from a regular place. For this reason, perform manual transmission repair already on a previously dismantled transmission. To do this, carry out the following actions:

Drain the oil from the manual transmission and disconnect the ground wires coming from the battery.
On Ford Transit cars with independent front suspension and type N or G gearboxes, you will need to lower the front suspension cross member by about 100 mm.
Remove the starter and air filter.
Separate the gear lever from the lever.
Separate the engine from the gearbox.
Remove the manual transmission from the car.

Professional manual transmission repair in Moscow with the provision of a long-term warranty for the operation of the equipment, not all service centers can perform. Our auto technical center provides comprehensive services for the maintenance and repair of manual transmissions using special equipment, tools and branded spare parts. Modern equipment and professional craftsmen in the shortest possible time will eliminate any malfunctions in the transmission. Gearbox repair we carry out it only after a thorough diagnosis, which is designed to determine the place of the defect, the reasons for its occurrence and the best options for its elimination. Quite often, it is not repairs that are required, but the adjustment of the operation of some mechanisms, which does not even require removal from the car. At the disposal of our staff is a large number of diagnostic equipment, fixtures and tools, with which you can quickly measure clearances, make adjustments, and rebuild the work of mechanisms.

If necessary, perform high-quality capital manual transmission repair in Moscow, our technicians will restore the gearbox to work with a malfunction of any level of complexity. We are ready to replace the following spare parts with branded samples:

oil seals;
gaskets;
bearings;
synchronizers;
gears;
details of the switching mechanism;
locking device and many others.

After the completion of the repair work, the mechanism must be run-in in order to fully check the complete operability and functioning of the manual transmission. You can always get more detailed information on the questions you are interested in by phone or by leaving a request-request on our website.

St. Petersburg, st. Preferred house 6P

Ford vehicles have been a leader in the commercial vehicle market for a long time. They are reliable, unpretentious in operation and versatile enough in the performance of their main functions.

Individual technical units are gradually being improved, the design of new generations of this car is changing. But its main qualities remain unchanged, which are so loved by our motorists.

The level of modern technology makes it possible to create cars targeted at the widest range of owners. They can carry cargo, passengers, or be used for daily travel around the city.

If the driver does not forget to service his vehicle on time, then you can drive without severe breakdowns that sometimes violate serious plans. Therefore, it is so important to do this for every car owner.

The choice of a good car service plays an important role in this matter, where they can carry out the whole range of diagnostics or repairs of your vehicle in one place.

This is especially true for some technical units that require special qualifications. For example, if you need to repair the Ford Transit checkpoint, then there is no need to even think that you can do this work yourself.

In order to have an idea for yourself when you may need to repair a Ford Transit box, you need to understand a little about its device and understand how it should work correctly.

Commercial vehicles of this brand can be equipped with 4 or 5-speed gearboxes. If there is a clutch in it, then its design provides for direct attachment to the engine and connection, using a propeller shaft, to the rear axle.

Regardless of its type, gears are installed in it for constant engagement. Gear shifting occurs thanks to one of the sliding couplings that lock the corresponding gear on the shaft.

Synchronizers that equalize the speed of the shaft and gears are installed in each forward gear, and on one of the Ford MT-75 gearboxes, also in reverse gears.

The front gears have helical gears, while the reverse gears are in a classic straight shape. The only exception is the same MT-75 box, which has helical gears in both directions.

The gearshift mechanism with cover and extension is bolted to the gearbox housing, just like the clutch housing.

The input and output shafts rotating in ball bearings are installed in a single line. The idler gear unit bearings and the pinion shaft pilot bearing are of a needle design.

Such needle bearings are also installed in driven gears rotating on the output shaft. Given the design features, the repair of the Ford Transit manual transmission may require high qualifications from the master.

Timely troubleshooting is one of the most rewarding skills for a motorist. Usually, during operation, unexpected breakdowns can occur, which do not always depend on certain circumstances.

You may notice oil leakage in the box. Then it is necessary to eliminate this problem as soon as possible by contacting the service center, where they can fix the leak and identify its cause.

Often, due to bearing wear, there is an abnormal noise during the operation of the gearbox, and gear shifting becomes difficult. Or even impossible, which is very inappropriate when you are on the road.

Also, the speeds can begin to turn off on their own, which clearly indicates a malfunction in the gearbox. After that, the road is only to the auto repair shop for repairs.

In any case, any violation in this technical unit requires immediate attention from the driver and service technician. Without the normal operation of this mechanism, it is impossible to drive a car.

Correct operation of this technical unit consists in clear and correct gear shifting while driving. If you do not do it well enough, then there is a risk of premature breakdown.

Oil leakage can occur due to worn oil seals or gaskets, which can then lead to more serious damage. Also, due to a violation of the fasteners, the crankcase cover may weaken.

Wear on bearings or gears is a common cause. Spline connections may become unusable or the synchronizer may fail. In this case, they must be replaced.

If there is a difficulty in shifting gears, then the reason for this may be a breakdown of the mechanism responsible for the performance of this function. The same gears and synchronizer are responsible for this.

If the locking device is faulty or the gears are very worn out, then the gears can be knocked out (shutdown). Replace defective parts as soon as possible.

Someone may be intimidated by going to a workshop for diagnostics. And, meanwhile, this is a very important stage on which the correctness of all future repairs depends. Therefore, you should not neglect the help of specialists who repair Ford Transit boxes almost every day.

In addition to the fact that the master will definitely listen to the owner of the car and take into account all the information received from him, he will certainly carefully check each technical unit himself.

For accurate diagnostics, the car service has modern equipment and tools that may only be needed to carry out it. The experience of the craftsmen allows you to notice the smallest malfunctions that a simple motorist will not pay attention to.

It is important to carry out all diagnostics and repairs in a workshop. Even if it seems to you that you can handle the repair yourself, no one will perform a Ford Transit gearbox repair as well as an experienced specialist.

Only an appeal to knowledgeable craftsmen can help to deal with the breakdown. At all stages, from diagnostics to repair, it is necessary to use a specialized tool and have high qualifications, which only they have.

After diagnostics, before starting work, oil is drained from the box. Further, according to a certain plan, the following stages of repair are carried out. As necessary, all defective parts are replaced, or this unit is completely replaced.

For such work, it is necessary to take into account certain factors that allow you to professionally do everything that may be required. The master from the car service necessarily gives a guarantee for the work he has done.

It is important not to be afraid of outside help and, if you need to replace the Ford Transit gearbox, contact a specialized workshop for help, where you will definitely be helped by solving this problem.

Often, motorists themselves become the culprits of problems with the gearbox. Careless driving greatly affects the resource of this complex technical unit.

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