MT 75 Manual Transmission and Clutch

Manual Transmission – Overhaul (transmission removed) (16 118 8)

Special Tools
16-041
15-030A Front transmission housing
Universal flange-holding remover and installer
wrench 16041

15030A
16-041-01
15-035 Adaptor for 16-041
Bearing ring installer
1604101
15035
16-042-A
15-036 Adaptor for 16-042 A-01
Countershaft roller bearing
installer 16042A

15036
16-042A-01
15-050A Threaded spindle
Remover (basic tool)
16042A01

15050A

16-043A
15-064 Drive flange oil seal installer
Adaptor for 15–035, bearing
cones 16043A

15064
16-044
15-068 Guide sleeve oil seal
Adaptor for 15–033, bearing installer
cones 16044

15068
16-045
15-091 Mounting bracket
Separator
16045

15091

16-050
15-092 Collet for 15-050 A
Bridge, remover
16050

15092
16-056
15-096 Remover
Installer
16056

15096
21-036A
16-040A Remover for pilot bearing
Guide sleeve wrench
21036A

PZ16040A

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 MT 75 Manual Transmission and Clutch

Materials
21-037B
Pilot bearing remover Cable ties
Sealer ESKM-4G242-A
21037B
High-temperature
ESDM-1C220-A
grease
21-051
Transmission fluid ESDM-2C186-A
Oil seal remover

21051
Proprietary Tools
Two-legged puller
21-103A
Internal extractor
Locator
30 mm socket wrench (double hexagon)
21103A
8 mm Allen key
14 mm Allen key
21-540 17 mm Allen key
Angle gauge
T40 Torx wrench
21540 9,5 mm twist drill bit

Workshop Equipment
Assembly stand

Dismantle
1. General notes.
Some synchroniser units and bearings are
identical and must be marked for reuse.
Mark the synchroniser units in the direction
of travel of the vehicle.
All the bearings are paired and must not
be mixed up.
Use soft jaws for all operations in a vice.

2. Drain off the transmission fluid

(transmission for diesel engine shown).

D1601150

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 MT 75 Manual Transmission and Clutch

3. Mount the transmission on an assembly

stand.
1 Screw the tool bolt into the threaded hole for
the oil drain plug and tighten it.
2
2 Secure the mounting bracket to the
16–045 transmission.

1
D1601151

4. Detach the pressure line and the bleed

screw.
1 Pull out the spring clip; disconnect the
quick-release coupling.
1
2 Remove the bleed screw.
2

D1601011

5. Remove the slave cylinder complete with

the release bearing.

D1601012

6. Unscrew the drive flange nut from the

mainshaft.

Use a 30 mm socket wrench.

Hold with the special tool.

Discard the nut.
15–030 A

D1601153

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 MT 75 Manual Transmission and Clutch

7. Pull off the drive flange.

15–092

D1601160 15–091

8. Remove the guide sleeve.

Remove the thrust washer.
16–040A

D1601154

Remove input shaft guide sleeve oil seal

9. Remove the radial oil seal.
Prise out the radial oil seal using a suitable
lever.

S1601148

10. Remove the input shaft circlip.

11. Remove the countershaft bearing
housing.
1 Remove the bearing housing locking plate.

1 2 Unscrew the bearing housing using a

17 mm Allen key.

D1601155

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 MT 75 Manual Transmission and Clutch

12. Remove the selector interlock

mechanism.
1 Remove the plug with a 14 mm Allen key.
2 Remove the spring, pin, ball and sleeve.

1
2
D1601156

13. Remove the reversing light switch and

2 the locking screw.
1
1 Reversing light switch
2 Locking plate locking screw.

D1601157

14. Unscrew the transmission housing bolts.

1 Housing flange (10 bolts).
2 Only slacken the bolt of the reverse gear
idler shaft (marked in blue).
1 3 Unscrew the bolt of the reverse gear idler
shaft (marked in blue).

3
2

D1601158

15. Prise out the radial oil seal.

21–051

D1601163

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 MT 75 Manual Transmission and Clutch

16. Remove the speedometer drive pinion

and worm gear.
Remove the blanking cover.

S1601149

NOTE: Do not drive out the housing locating

dowels.
17. Separate the transmission housing
halves.
NOTE: Only apply the levers to the reinforcing
ribs.

J1601160

CAUTION: Take care not to apply

excessive pressure to the input shaft
2 16–041–01 through the special tool as this could
damage the 4th gear synchroniser ring.
16–041 1
18. Pull off the front transmission housing.
NOTE: Hold the special tool with a drift.
1 Attach the puller.
2 Screw the adaptor into the threaded hole of
the guide sleeve.
D1601159
If necessary, assist with levers.

19. Remove the 3rd/4th gear selector fork.

1
Move the main selector shaft to the neutral
position.
1 Pull out the auxiliary selector shaft.
2
2 Remove the 3rd/4th gear selector fork.

D1601161

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 MT 75 Manual Transmission and Clutch

20. Remove the second retaining bolt of the

reverse gear idler shaft (marked in blue)
and the magnetic disc.

J1601168

CAUTION: Move the selector shaft to the

neutral position so that the locating pin
does not break off the shift finger holder.
NOTE: Locate the puller on the housing bosses.
21. Press the mainshaft out of the bearing in
the rear transmission housing.

J1601169

22. Remove the main selector shaft with the

selector fork.
23. Lift out the complete gear train.

Dismantle main selector shaft

1
NOTE: Catch the two balls from the spring
carrier.
24. Dismantle main selector shaft
1 Remove the circlip.
2 Remove the spring cup, spring and spring
carrier.
2

D1601164

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 MT 75 Manual Transmission and Clutch

25. Dismantle the main selector shaft

3 (continued).
1
1 Drive the roll pin out of the shift finger holder
and the main selector shaft.
2 Remove the shift finger holder.
3 Remove the 1st/2nd gear selector fork.
2

D1601165

26. Dismantle the main selector shaft

(continued).
2
1 Remove the locking sleeve.
2 Drive the roll pin out of the shift finger and
the main selector shaft.
3 Remove the shift finger.

1 3
D1601166

Dismantle rear transmission housing

27. Remove the countershaft rear roller
bearing.
Use a proprietary internal extractor.

J1601171

28. Remove the selector gate.

D1601168

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 MT 75 Manual Transmission and Clutch

29. Drive out the main selector shaft ball

21–103 A sleeve together with the radial oil seal.

D1601169

30. Unscrew the retaining bolts of the

mainshaft ball bearing.

D1601167

31. Remove the mainshaft ball bearing.

Drive out the mainshaft ball bearing using a
suitable length of tube.

D1601171

Dismantle front transmission housing

21–037 B
NOTE: Insert a spacer (approx. 63 mm) in the
hole.
NOTE: Use remover 21-036 A with the thrust
element of 21-037 B.
32. Remove the main selector shaft ball
sleeve.
21–036 A

D1601172

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 MT 75 Manual Transmission and Clutch

33. Remove the input shaft ball bearing.

Use a suitable length of tube or Special Tool
15-096.

D1601173

CAUTION: Take care not to damage the

bearing housing thread in the housing.
34. Drive out the countershaft roller bearing.

S1601150

Dismantle mainshaft
35. General notes.

CAUTION: From build date 17.8.1994

onwards (see table on page 2, General
Specifications) the synchroniser rings for
1st, 2nd and 3rd gear have a taper angle
of 7
and are coated with molybdenum.
The synchroniser rings for 4th, 5th and
reverse gear have a taper angle of 6,5

as previously.
Vehicles manufactured from build date
17. 6.1996 are fitted with a 1st/2nd gear
double synchroniser unit.
When the shaft is dismantled, the
synchroniser rings and synchroniser units
must be marked.
When dismantling the synchroniser units,
also mark the synchroniser hubs in relation
to the shift rings.

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 MT 75 Manual Transmission and Clutch

36. Remove the input shaft with the 4th gear

synchroniser ring from the mainshaft.
3
1 Input shaft
2 4th gear synchroniser ring
3 Roller bearing

1 2
J1601179

37. Remove the 5th gear wheel with the

synchroniser ring from the mainshaft.
1 5th gear wheel
1
2 Needle roller bearing

J1601180

:WARNING: The synchroniser units must

not be allowed to fall apart as there is a
danger of injury from springs, blocker bars
and balls.

1 38. Remove the 3rd/4th gear synchroniser

unit with the 3rd gear wheel.

2
Clamp the mainshaft in a vice with the

output shaft pointing downwards.
3

Remove the circlip.
1 3rd/4th gear synchroniser unit
J1601182
2 3rd/4th gear wheel
3 Needle roller bearing

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 MT 75 Manual Transmission and Clutch

39. Pull off the 3rd gear bearing ring.

16–056 Locate the puller in the recesses in the

bearing ring.

J1601183

NOTE: Mark the parts.

40. Remove the 2nd gear wheel with the
needle roller bearing and synchroniser
ring.

J1601184

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 MT 75 Manual Transmission and Clutch

Vehicles manufactured from build date

17. 6. 1996 are fitted with a 1st/2nd gear
synchroniser unit.
1 NOTE: Mark the shift ring for the gear
synchroniser. Components are paired.
41. Remove the 1st/2nd gear synchroniser
2 unit with the 1st gear wheel.

Remove the circlip for the 1st/2nd gear
synchroniser unit.
3
1 1st/2nd gear synchroniser unit
ELS1601195
2 1st gear wheel
3 Needle roller bearing

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 MT 75 Manual Transmission and Clutch

NOTE: Mark the shift ring for the gear

synchroniser. The components are paired.
1 42. Remove the 5th/reverse gear
synchroniser unit with the reverse gear
wheel and needle roller bearing.
2
Clamp the mainshaft the other way round in
the vice.

3
Circlip
1 Synchroniser unit
J1601188 2 Reverse gear wheel
3 Needle roller bearing

:WARNING: Take care when removing the

shift ring from the synchroniser hub. The
1 3 1
balls and blocker bars are spring-loaded.
43. Dismantle the synchroniser unit.
1 Synchroniser rings
2 Shift ring
3 Synchroniser hub
5
4 Ball and blocker bar
2
4 5 Compression spring
ELS1601194

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 MT 75 Manual Transmission and Clutch

Vehicles manufactured from built date

1 2 3 17. 6.1996 are fitted with a 1st/2nd gear double
synchroniser unit.
44. Double synchroniser unit components.
1 Outer synchroniser ring
2 Inner synchroniser ring
3 Synchroniser cone
4 Gear wheel
4
ELS1601193

Dismantle countershaft
NOTE: Insert the puller in the annular groove
provided in the ring.
15–050 A 45. Pull the inner ring off the countershaft.

16–050

J1601190

Dismantle reverse gear idler shaft

3 1 46. Dismantle the reverse gear idler shaft.
4
1 Drive out the roll pin.
2 Bearing housing
3 Idler
4 Needle roller bearing

2
J1601191

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 MT 75 Manual Transmission and Clutch

Assemble transmission
47. General notes.

Lubricate all moving parts with transmission
fluid before or during assembly.

Renew all the circlips, oil seals and
self-locking nuts.

Measure the circlips so that they fit into their
grooves without free play.
48. Preparatory operations.
J1601707
Clean and check all parts thoroughly and
renew if necessary.

Assemble rear transmission housing

NOTE: If the rear transmission housing is
renewed, a new detent pin must be fitted.
69,0 mm 0,3 mm The distance from the tip of the detent pin to the
housing mating face must be 69,0 ± 0,3 mm.

D1601675

49. Fit the mainshaft ball bearing.

15–064 Use only the spindle of 15-035.

15–035
15–035

D1601671 15–068

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 MT 75 Manual Transmission and Clutch

50. Secure the mainshaft ball bearing with

24 Nm bolts and washers.

D1601667

51. Drive in the main selector shaft ball

21–103 A sleeve flush.

D1601169

52. Fit the main selector shaft radial oil seal.

D1601670

NOTE: Use new locating bolts.

10 Nm 53. Fit the selector gate.

D1601668

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 MT 75 Manual Transmission and Clutch

54. Drive in the countershaft roller bearing as

far as the stop.
15–036

D1601179

Assemble front transmission housing

1
55. Fit the input shaft ball bearing.
2 1 Fit the circlip in the annular groove of the
ball bearing.
15–064
2 Drive in the ball bearing from the clutch side

PZJ1601677

NOTE: Do not drive the roller bearing in flush

but allow it to protrude approx. 2 mm on the
15–036 inside.
56. Fit the countershaft roller bearing.

2,0 mm

J1601678

57. Drive in the main selector shaft ball

sleeve flush.

21–103 A

D1601672

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 MT 75 Manual Transmission and Clutch

Install input shaft guide sleeve oil seal

NOTE: The sealing lip must face the tool on
installation.
58. Drive in the radial oil seal.
16–044

S1601648

Assemble reverse gear idler shaft

2 4 NOTE: Do not fit the bearing housing twisted.
1 The threaded holes must line up with one
another.
59. Assemble the reverse gear idler shaft.
1 Needle roller bearing
2 Idler
3 Bearing housing
3
J1601706 4 Drive in the roll pin.

Assemble countershaft
60. Fit the bearing rings.
Heat the bearing rings to approx. 100
C and
slide them on.

J1601690

Assemble main selector shaft

NOTE: The shift finger must point in the
opposite direction to the actuating pin of the
reversing light switch.
61. Assemble main selector shaft
1 Slide the shift finger onto the main selector
shaft and secure it with a roll pin.
2 Slide the locking sleeve onto the selector
2 1 shaft and shift finger.
D1601666

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 MT 75 Manual Transmission and Clutch

NOTE: The roll pin must be aligned centrally.

1
62. Assemble the selector shaft (continued).
1 Fit the 1st/2nd gear selector fork on the
selector shaft.
2 Slide the shift finger holder onto the selector
shaft and secure it with a roll pin.
2

D1601665

63. Assemble the main selector shaft

3 (continued).
1 Fit the spring carrier on the selector shaft
with two balls.
2 Fit the spring and spring cup.
3 Secure them with a circlip.

2
1

D1601664

Assemble mainshaft
1 3 1
64. Assemble the synchroniser unit.
1 Fit the compression springs.
2 Synchroniser hub
3 Ball and blocker bar
4 Position the shift ring correctly and slide it
5 on.
2 5 Fit the synchroniser rings.
4
ELS1601194

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 MT 75 Manual Transmission and Clutch

NOTE: Marking
65. Fit the needle roller bearing and reverse
gear wheel with the synchroniser unit.

Clamp the mainshaft in a vice with the
output end pointing upwards.
2
1 Reverse gear wheel

1 2 Synchroniser unit
3 Select a circlip which fits without free play
3 and fit it.
PZJ1601694

Available circlips:
2,03 mm
2,07 mm
2,11 mm
2,15 mm

Vehicles manufactured from build date

17. 6. 1996 are fitted with a 1st/2nd gear double
synchroniser unit.

3 NOTE: Marking
66. Fit the 1st/2nd gear synchroniser unit.

Clamp the mainshaft the other way round.
2 1 Fit the needle roller bearing.
2 Fit the 1st gear wheel.
1 3 Fit the 1st/2nd gear synchroniser unit.
J1601686

Select a circlip which fits without free play
and fit it.

Available circlips:
2,03 mm
2,07 mm
2,11 mm
2,15 mm

09/97 Scorpio ’95 00-01-21

 MT 75 Manual Transmission and Clutch

67. Fit the synchroniser ring, needle roller

bearing and 2nd gear wheel.
1 Needle roller bearing
2 Synchroniser ring
3 3 2nd gear wheel
2
1

J1601684

NOTE: Slide the inner bearing ring onto the

mainshaft as far as the shoulder.
68. Fit the 3rd gear wheel inner bearing ring.
Heat the inner bearing ring to approx.
100
C.

J1601683

NOTE: Fit the synchroniser unit with the small

collar facing upwards.
69. Fit the 3rd/4th gear synchroniser unit.

Fit the needle roller bearing.
1 Fit the 3rd gear wheel.
2 Fit the 3rd/4th gear synchroniser unit.
2
1
Select a circlip which fits without free play
and fit it.

Available circlips:
J1601682
1,99 mm
2,03 mm
2,07 mm
2,11 mm
2,15 mm
2,19 mm

09/97 Scorpio ’95 00-01-22

 MT 75 Manual Transmission and Clutch

70. Fit the 5th gear wheel.

Clamp the mainshaft the other way round.

3 1 Needle roller bearing

2 5th gear synchroniser ring

2 3 5th gear wheel

1

J1601680

71. Fit the input shaft.

3
Clamp the mainshaft the other way round.

1 Roller bearing

2 2 4th gear synchroniser ring

3 Input shaft

J1601679

72. Assemble the countershaft with the

mainshaft and secure the assembly with
a cable tie.

D1601677

NOTE: The 1st/2nd gear selector fork must

engage in the 1st/2nd gear synchroniser unit in
the middle.
73. Fit the main selector shaft.

D1601676

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 MT 75 Manual Transmission and Clutch

74. Assemble the reverse gear idler with the

countershaft and mainshaft assembly.

The end of the shaft with the flat points
upwards.

Secure the assembly with a cable tie.

D1601679

75. Fit the 5th/reverse gear selector fork in

the lower synchroniser unit.
The outrigger points upwards.

D1601678

76. Fit the complete gear assembly in the

rear transmission housing.
77. Slide the speedometer worm gear onto
the mainshaft.

D1601681

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 MT 75 Manual Transmission and Clutch

NOTE: During installation, guide the main

selector shaft into the ball sleeve correctly.
NOTE: The distance between the countershaft
and the synchroniser ring must not be zero.
78. Draw the mainshaft into the rear
transmission housing.
1 Screw the spindle into the mainshaft.
2 Fit the adaptor.

Guide the countershaft into the rear roller
bearing.
79. Remove the speedometer worm gear.

1
16–042 A

16–042 A–01

D1601682

80. Insert the retaining bolt for the reverse

gear idler shaft and screw it up finger
tight.

Remove the cable ties from the gear
assembly.

Fit the magnetic disc.

J1601168

NOTE: The chamfered end of the selector shaft

points upwards.
81. Fit the 3rd/4th gear selector fork in the
upper synchroniser unit and the auxiliary
selector shaft.

D1601661

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 MT 75 Manual Transmission and Clutch

82. Fit the front transmission housing.

Position three spacers approx. 25 mm in
length between the housing sections.

J1601703

83. Draw on the front transmission housing.

16–041–01 1 1 Attach the adaptor.

2 Attach the two clamping shells to the input
16–041 shaft.
3 Secure them with the sleeve.

2 3
D1601659

NOTE: During installation, guide the

countershaft correctly into the bearing.
1 Tighten the flange bolts within 15 minutes.
84. Draw on the front transmission housing
16–041 (continued).

2 1 Slide the large sleeve over the clamping

shells and sleeve.

Remove the spacers and apply sealer to the
mating faces of the rear transmission
housing.
D1601662
Apply sealer (ESKM-4G242-A) to the inside
of the mating faces.
2 Draw on the housing.

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 MT 75 Manual Transmission and Clutch

85. Bolt the housing halves together.

1 Insert two housing bolts on opposite sides
and draw the housing sections together.

Fit the remaining eight bolts and tighten
24 Nm
1 them.
2 Tighten the bolts of the reverse gear idler
shaft (both bolts are marked in blue).
2

32 Nm
D1601658

86. Fit the reversing light switch and the

14 Nm locking screw.
1 33 Nm
1 Reversing light switch
2 2 Locking plate locking screw

D1601657

87. Fit the selector interlock mechanism.

1 Insert the sleeve, ball, pin and spring.
2 Apply sealer (ESKM-4G242-A) and screw in
the plug (14 mm Allen key).
2

24 Nm

1
D1601656

88. Fit the speedometer worm gear.

89. Fit the speedometer drive pinion in the
rear transmission housing.
Apply sealer (ESKM-4G242-A) and fit the
speedometer drive pinion cap.

S1601649

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 MT 75 Manual Transmission and Clutch

90. Fit the drive flange radial oil seal.

16–043 A
D1601683

91. Draw the drive flange onto the mainshaft.

Fit the flange.
2
1 Screw the spindle into the mainshaft.
16–042 A
2 Screw on the adaptor.

Hold the spindle with a drift.

16–042 A–01
D1601660

92. Secure the drive flange with a new nut.

200 Nm Hold the drive flange.

15–030 A

D1601653

93. Fit the input shaft circlip.

Select a circlip which fits without free play
and fit it.

Available circlips:
2,26 mm
2,30 mm
2,34 mm
2,38 mm
D1601655 2,42 mm

09/97 Scorpio ’95 00-01-28

 MT 75 Manual Transmission and Clutch

94. Prepare the guide sleeve for installation.

1 Fit a new O-ring.
2 2 Stick the thrust washer in place with grease.

S1601651

95. Secure the guide sleeve.

16–040A

250 Nm

S1601652

96. Fit the countershaft bearing housing

using a new O-ring.

Grease the O-ring.

Screw in the bearing housing with a 17-mm
Allen key.
40 Nm

S1601653

97. Unscrew the bearing housing 80
.

21–540

80

S1601654

09/97 Scorpio ’95 00-01-29

 MT 75 Manual Transmission and Clutch

NOTE: Tilt the clutch housing downwards at

least 45
.
98. Drive the countershaft bearing home
against the bearing housing.
Strike two blows on each of the bosses
using a brass drift and hammer. This will
drive the bearing home against the bearing
housing.

S1601655

CAUTION: A minimum torque of 6 Nm

must be achieved.
min. 6 Nm 99. Tighten the bearing housing 20
and
secure it with the locking plate.
21–540 If the 6 Nm are not achieved,
25 Nm sub-operations 97. to 99. must be repeated.
20

S1601656

100. Fit the slave cylinder complete with the

release bearing.

10 Nm

D1601512

NOTE: Make sure that the quick-release

coupling is locked securely.
101. Fit the clutch pressure line and bleed
screw.
1
1 Connect the quick-release coupling.
2
2 Screw in the bleed screw.

D1601511

09/97 Scorpio ’95 00-01-30

 MT 75 Manual Transmission and Clutch

102. Detach the transmission from the

assembly stand and detach the mounting
bracket.
103. Tighten the oil drain plug.

35 Nm
D1601650

09/97 Scorpio ’95 00-01-31