Replacement of hinges of equal angular speeds (CV joint). Replacement of constant velocity joints (CV joints) Tools and materials

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Ford Fusion / Fiesta. Replacement of constant velocity joints

Replacement of constant velocity joints (CV joints)

If knocks are heard in the front drive while the car is moving in turns, check the constant velocity joints. If, when the drive shaft is rocked by hand, play is felt or protective covers are torn, then such a hinge must be replaced. It makes little sense to disassemble the outer hinge (Birfield type) of the front wheel drive. This work is very time-consuming, and if the cover is torn, the dirt that gets into the hinge quickly makes the hinge parts unusable. You cannot replace the hinge parts individually, so the best solution is to replace the hinge assembly. In extreme cases, disassembly is allowed to replace the lubrication of the inner hinge of the right front wheel drive (Tripod type) as simpler and less susceptible to water and road dirt. The appearance of traces of grease on the hinge indicates that the cover is torn.
You will need: flat-blade screwdriver, side cutters, barb, hammer, circlip pliers.
1. Remove the front wheel drive assembly
2. Clean the parts and inspect the drive:

- the outer CV joint should turn with a slight effort, without jerking and jamming, radial and axial play. If present, replace the hinge;

– the inner hinge of the wheel drive should move in the angular and axial directions with a slight effort, while jerks, jamming and radial play should not be felt. Otherwise, replace the inner joint;

– the protective covers of the outer and inner hinges must not have cracks or ruptures. Replace damaged cases;

– The wheel drive shaft must not be deformed. Replace warped shaft.

3. To replace the outer hinge or its cover, disconnect with a screwdriver or bite with side cutters the clamp lock of the large cover of the outer hinge and remove the clamp.

NOTE

Clamps for fastening the protective covers of the constant-velocity hinges are disposable, replace them with new ones during assembly. As a rule, clamps are included in the kit of a new hinge.

4. Similarly remove a small collar of fastening of a cover.

5. Slide the protective cover off the hinge housing…

6. ... and knock the hinge cage off the shaft with a hammer through the beard, overcoming the force of the retaining ring.
7. Remove the outer joint from the shaft splines.
WARNING
Disassembly of the outer hinge is not allowed.
8. Remove the circlip by prying it out of the shaft groove with a screwdriver.
NOTE
When assembling, replace the circlip with a new one. As a rule, the ring is included in the kit of the new hinge.

9. Remove the protective cover from the drive shaft.
NOTE
When installing the hinge, replace the protective cover with a new one. Usually a boot is included with the new hinge.

10. Before installing a new outer hinge, fill its cavity with grease (if the hinge was not lubricated by the manufacturer) in the amount of (135 ± 6) g: put (70 ± 3) g in the hinge, and (65 ± 3) g in the case.

NOTE

11. Install the outer hinge cover and hinge in the reverse order of removal.

12. To remove the inner hinge of the drive of the right front wheel, remove the clamps that secure the hinge cover to its body ...

13. ... and to the shaft.

14. Disconnect the inner pivot housing from the drive.

15. Unclench the retaining ring of the hinge hub with a puller ...

16. ... and remove the ring, removing it from the groove of the shaft.

NOTE

Grease has been removed from the hinge for clarity.

17. Remove the hub with rollers from the splines of the shaft ...

18. ... and remove the protective cover from the shaft.
NOTE
When installing the hinge, replace the protective cover with a new one. It is usually included with the new hinge.
19. Wash all metal parts with kerosene until the old grease is completely removed.

20. Before assembly, fill the cavity of the body and the boot of the inner hinge with grease in the amount of (145±6) g: put (100±3) g into the hinge, and (45±3) g into the boot.
NOTE
In the absence of a lubricant recommended by the manufacturer, domestic molybdenum grease SHRUS-4 can be used.
21. Assemble the right front wheel drive inner joint in the reverse order of disassembly.
22. After assembling and installing the hinges, check the fit of the belts of the covers and the reliability of fastening the clamps. Covers should not turn on the hinges and the shaft, and the clamps - on the covers. Otherwise, replace the clamps.

Ford Fusion is an inexpensive but reliable family car. This compact-looking car has a good interior capacity, high-quality engines and a durable design.

Although Fusion is not considered the most popular representative, there is a certain demand for this model.

Cars are valued for good assembly, reliability and ease of maintenance. A number of activities can be done by hand, including the replacement of working fluids.

If you know how to check the gearbox oil on a Ford Fusion, changing the fluid will take you very little time and effort. The procedure consists of several consecutive steps. By following the instructions and adhering to safety rules, you will save money on car service services and gain additional skills and experience in servicing your car.

Replacement frequency

Most car owners already know that it is impossible to rely completely on the factory manual from foreign automakers.

Yes, the instructions often indicate that the presented frequency of replacing consumables is based on difficult operating conditions, cold winters, etc. But in reality, the sight is on average European indicators of road quality and climate.

Our conditions are somewhat different. The quality of the road surface is lower, the winter is much colder. Because of this, the specified oil change period does not always correspond to reality.

In the case of a Ford Fusion car, American experts recommend changing the oil in the box every 70 thousand kilometers. Considering the operating conditions in Russia, Ukraine and the CIS countries, the actual interval between changing the fluid in the gearbox is up to 60 thousand kilometers.

The experience of some motorists shows that with regular operation of the car under serious loads, the interservice period is reduced to 40-50 thousand kilometers.

To understand exactly whether it is time to change the oil or not, you need to monitor the behavior of your car, check its condition and level. There are several main criteria by which it is possible to identify oil wear and decide on its premature replacement:

1. drops to the minimum. Here you can get by with a simple topping up of fresh transmission fluid. But if the oil has not been changed for a long time, you should not mix the old worn-out lubricant with the new one. The effect will be minimal, and the node will continue to wear out.
2. The color of the liquid has changed. The most informative method for determining the degree of gear oil wear. The loss of physico-chemical properties of the composition is indicated by its black or dark brown color. If you see oil in this condition, it must be changed in the near future.
3. Smell. Fresh oil, which retains its characteristics, has a rather pleasant, mild smell. If the aroma has changed, it has become sharp and unpleasant, this indicates a strong deterioration of the mixture. Replacement required.

In the case of a manual transmission, changing the oil in the gearbox can be done by hand in a couple of hours. To do this, you will first need to choose a high-quality lubricant that will meet the requirements of the car manufacturer.

Oil selection

Fusion uses synthetic gear oils. Alternative choices could be:

• Hochleistungs-Getriebeoil by Liqui Moly (GL5);
• Castrol TAF X (GL4/5);
• Castrol Syntrans Multivehicle;
• Mobil 80W90;
• total.

There are no hard limits in terms of gear oil manufacturers. But try to use only high-quality and effective formulations. When changing the oil, it is recommended to use a new similar one. If you want to switch to a different lubricant, then it is worth thoroughly cleaning the transmission case.

Here it already makes sense to seek help from a good service station. Using the hardware method, they will clean the crankcase, which will allow you to fill in a new brand of oil without fear.

If you are lucky or if you make an effort, you can theoretically find the original factory oil. At the assembly stage of Ford Fusion cars, the Ford proprietary compound with a viscosity of 75W90 (its specification WSD-M2C200-C) is poured into the oil boat of their manual transmissions.

The total filling volume of a manual gearbox on a manual transmission is 2.3 liters. But completely draining the oil is unlikely to succeed. To do this, you will have to contact a car service equipped with specialized equipment. In garage conditions, it is possible to remove about 1.8 - 2 liters from the crankcase. Therefore, feel free to buy a 2.0 liter canister. This amount of gear lubricant will be enough.

Castrol Syntrans Multivehicle is a good option for an oil change

Oil level check and top up

During the operation of the car, owners are required to monitor the condition and level of all working fluids and consumables.

In the case of a manual transmission, the level is checked relatively quickly. Much to the regret of many motorists, Ford engineers did not provide a dipstick for the Fusion model. Therefore, you have to find your own solutions to determine the amount of composition inside the oil sump.

Let's take a closer look at how to check the oil level in the gearbox of your Ford Fusion yourself.

1. The machine must be placed on a level, level surface. It is best to have a pit, overpass or lift available. Climbing under a vehicle that has been jacked up is dangerous.
2. Below is a plastic box that hides the gearbox housing. It is held on special clamps. These latches should be carefully pressed out so as not to break.
3. Next, the cover of the casing of the gearbox mechanism is removed.
4. The next step is to unscrew the filler plug. You will find it directly on the car's manual transmission housing.
5. Take a small piece of wire. It needs to be bent so as to get the letter G. Bend a small edge along the length so that the wire fits into the gearbox housing.
6. Insert a wire into the crankcase and check the transmission fluid level.
7. At a normal level, the oil is located at the edge of the filler hole or slightly below this mark. If there is a shortage of transmission fluid, it will need to be topped up to the desired level.
8. In case of low oil content in the gearbox housing, use a special syringe. Type in it a small amount of oil that you used earlier to change the oil in the manual transmission. Pour the compound until it starts to come out back through the oil filler neck.

It remains only to wipe the hole, close the lid and reassemble the assembly.

The absence of a dipstick somewhat complicates the banal check of the oil level in the gearbox housing. But if you do not carry out such events at least once a year, there is a chance to miss the moment of heavy wear of the gear oil. The operation of the box on poor lubrication turns into breakdowns and expensive gearbox repairs.

The official instruction manual tells motorists that on Ford Fusion cars, a full replacement of the transmission fluid is not required during the entire life of the manual transmission.

This rule can be followed by simply adding fresh oil to the crankcase periodically. But it is not always possible to fill in the same lubricant throughout the entire period. Switching to an alternative brand of fluid requires a mandatory complete replacement.

Also, the operation of a car in oil, which is only partially updated, threatens to quickly fail the manual transmission. This is normal for the American and European market, where after 5 years of service, the machines are simply sent for recycling and new ones are bought.

Our cars serve for 10-20 years. If you periodically carry out a complete drain of mining and pour fresh oil into the transmission crankcase, you will be able to significantly extend its service life. This will help to avoid replacing the box for at least 10 years. Yet Ford knows how to build good cars. Their manual transmissions are much more reliable than automatic transmissions. Although it has always been like this for everyone.

Tools and materials

If you have ever topped up your Ford Fusion with transmission fluid, then the replacement procedure will seem like a simple and quick process.

For work, you will need to prepare some tools and materials:

• hex key size 8 (8 mm.);
• syringe;
• socket wrench 19;
• screwdrivers;
• rags;
• empty containers for testing;
• pit, lift or overpass;
• fresh gear oil;
• overalls.

Remember that oils, even if their characteristics are identical, are by no means impossible. Therefore, when topping up, use only the grease that was filled there.

When replacing, a small amount of old oil is allowed, since the main part can be drained. Residues on the walls will not do much harm to the gearbox.

Step-by-step instruction

If the time has come when it is time to change the gearbox oil on a Ford Fusion car, devote a few hours to this issue.

Beginners may have problems at the stage of dismantling and reassembly. The drain itself and the filling of a new transmission fluid require no more than 30 minutes.

Try to follow the instructions clearly and follow the safety rules. We are talking about hot oil and a heavy car.

1. Warm up the car to operating temperatures. You can just get on the road and drive a few kilometers, shifting all the gears to the manual transmission.
2. Drive into the garage, put the car over a pit, overpass or lift it with a lift. The surface on which the vehicle is parked must be flat and level. This position will drain the maximum amount of lubricant from the manual transmission.
3. Before changing the oil, you will have to get to the drain hole. To do this, the crankcase protection of the power unit is removed. A protective cover is provided on the gearbox itself under the bottom of the machine. It is made of plastic, held on by latches, so there should be no problems with manually removing the latches.
4. There are also side parts of the box made of plastic. They are fixed with screws. There is no real need to remove them. Although if you dismantle the elements, it will be more convenient to perform subsequent operations.
5. Find two transmission cables. Carter box is just behind them. There are 2 plugs in the crankcase itself. As you already understood, one serves to drain the waste, and the second to fill the transmission fluid. The very fact of the presence of a drain plug already indicates that the plant provides for the replacement of the working staff in the Ford Fusion manual transmission.
6. To change the oil, you need to unscrew the top plug. To do this, use a hex wrench. With prolonged use of the car, the cover may boil. Because of this, dismantling is somewhat more complicated. Put in more physical effort or use a product like WD40. This will make it a little easier to remove the plug.
7. A little lower is the second plug, which closes the drain hole. Twist it until the old oil starts to come out. It is not necessary to completely unscrew the plug. These are redundant manipulations.
8. Place an empty container under the drain hole. Wait until all the liquid has drained out of it. If you warmed up the oil, then this process will take no more than 15 minutes.
9. While the oil is draining, check the condition of the magnets on the plugs. They are installed there specifically for collecting metal shavings. Therefore, be sure to clean the magnets. Replace the drain plug when oil stops flowing out of the transmission case.
10. Take the filling syringe, fill it with fresh oil. Gradually fill the gearbox housing. Usually it is possible to drain about 2 liters of mining. Therefore, you will need to fill in a similar amount.
11. Fill the oil with a syringe until it starts to flow back through the top. Wipe the oily area with a dry cloth and screw on the plug.
12. Recheck the fluid level. If necessary, add the missing lubricant to the crankcase of the manual transmission of your Ford Fusion.

If there are no signs of leakage on the surface of the oil filler hole of the box, you can assemble the assembly in the reverse order.

This completes the procedure for changing the oil in the gearbox on a Ford Fusion car. There is nothing complicated here, because this task can be solved on your own.

Ford Fusion belongs to the category of reliable and unpretentious cars. But he still needs care, supervision and timely maintenance.

The car owner is able to independently notice problems with the manual transmission in time if he pays attention to the oil and its color, smell and viscosity.

1. If severe wear of the friction linings has begun, this can be identified by the dark color of the lubricant in the gearbox housing.
2. If water gets into the crankcase, which usually happens on short trips over short distances, the oil becomes milky.
3. It happens that the amount of lubricant is at a high level, but the gearbox still overheats. A similar problem is identified by the sticky consistency of the gear oil.
4. The fact that the oil filter is clogged is indicated by the presence of metal chips in the oil.

If you notice one of these signs when you next check the level and condition of the fluid in the gearbox housing, be sure to fix the problem. Simply topping up will not solve the problem. Further operation of a car with a faulty gearbox will lead to the final failure of the transmission on the Ford Fusion. This will already result in an expensive repair or the need to replace the entire box.

The first Fusion was built on the basis of the Fiesta, but has more impressive dimensions: length - 4.02 m, width - 1.708 m. The American manufacturer has created a cross between a hatchback, a crossover and a compact van. Since the car belongs to the UAV class and is designed for active driving in urban areas, the company's engineers had to think over an extensive line of gearboxes for the Ford Fusion. Simplicity of control needed to be combined with maneuverability and quick switching, so the developers thought of three different boxes of the Ford Fusion Durashift series:

1) Automatic - a classic four-speed automatic with an electronic control system. It was installed in tandem with a 1.6-liter 100-horsepower engine (a car in this configuration accelerates to hundreds in 13.1 s). Among the advantages of the box are soft switching, quick response to pressing the gas.

Automatic transmission Durashift Automatic has different driving modes. For example, "kick-down", in which the gear is automatically downshifted and the fastest acceleration occurs. To drive over rough terrain, mountains, it is enough to switch the automatic transmission lever to the appropriate mode - the electronic system will independently select the optimal gear, taking into account the angle of the slope. Almost the same thing happens when driving down a slope: the automatic downshifts to slow down the Ford Fusion with the help of the engine. A working fluid temperature sensor is mounted in the box, which initiates different driving modes, saving transmission components from premature wear. For dynamic driving on the highway, you can put the automatic transmission in the Overdrive position to eliminate fourth gear and achieve a sharp shift.

The automatic four-speed Ford Fusion is marked Aisin AW80-40 and is controlled by a computer that is synchronized with the engine ECU. The first prototype of the box was developed by Toyota for small cars of its own production: Vitz, Yaris, Corolla. Every 80-100 thousand km, you need to pour new oil into the Ford Fusion box and change the filter equipped with a metal mesh. We insist that even with the perfect operation of the automatic transmission, it is necessary to inspect and diagnose the unit prophylactically. After all, the wear of the rings leads to the production of friction clutches, which can provoke serious breakdowns. If the clutches are changed in a timely manner, the correct gear shifting and normal clearances of the clutch packs will be maintained.

Immediately contact the technical center "S-Auto" if:

• Automatic transmission slips.
• The machine went into emergency mode.
• Vibration is felt, jerks when switching.
• There were braking, noises, transmission shocks.
• It is necessary to change the oil after a run of 100 thousand km (we recommend using branded oil marked WSS-M2C-924-A or choosing high-quality analogues).

2) EST - Ford Fusion robotic gearbox, which was used in tandem with a 1.4-liter gasoline engine. It is designed for maneuverable driving around the city and, unlike the machine, contributes to fuel economy. The mechanical basis is the IB5 manual transmission, which was equipped with the Focus of the first and second generations. The design also includes an ECU for selecting a suitable gear, a clutch release mechanism, and an electro-hydraulic type unit (built on the principle of a high-speed pump). The driver has two modes available: automatic and manual (sequential). When the engine is stopped, the clutch is automatically engaged so that the car can be parked in any gear.

Durashift EST has built-in security features:

• Starting the motor is possible only with the brake pressed, when the robot is in the "Neutral" mode.
• To switch to mode D from N, you need to depress the brake pedal.
• The Ford Fusion transmission ECU blocks manual shifting if the engine speed and RPM do not match the selected gear.
• If the manual mode is on, when decelerating, a lower gear is automatically engaged.

The Fusion robot box has obvious disadvantages: due to the peculiarities of the clutch operation, synchronizers wear out quickly, and to save money in automatic mode, overdrive is constantly engaged, which causes some discomfort. Many S-Auto customers also talk about other disadvantages of manual transmissions associated with electric motors, wiring rotting under the influence of moisture. All these problems can be easily eliminated by our masters (sometimes it turns out that typical breakdowns are caused by a banal violation of operational standards).

3) Durashift five-speed manual transmission - comes as standard with Fusion, designed on the basis of a two-shaft scheme. The clutch housing is attached to the manual transmission housing. The “childhood disease” of a mechanical transmission is howling.

Our technicians can fix common and rare problems. For example, the tight movement of the manual transmission lever is associated with the souring of the gear selection mechanism. During the repair, we dismantle the outer box and other structural elements, clean and lubricate the working surfaces. In critical situations, the lever may be skewed, which complicates the repair of the Ford Fusion manual transmission. Please note that the oil level should not go beyond the lower edge of the filler neck. Otherwise, it is necessary to top up (brand of factory lubricant - WSD-M2C-200-C). When choosing oil, we give preference to proven products from Castrol, Mobil, etc. This guarantees reliable operation of synchronizers, smooth shifting at sub-zero temperatures, minimization of noise and operating temperatures, and control of deposits.

Ford Fusion Gearbox Parts

Ford Fusion vehicles are fitted with a Durashift five-speed manual transmission as standard.

On request, Ford Fusion vehicles with a 1.4-liter gasoline engine can be equipped with a 5-speed manual robotic gearbox Durashift EST with sequential manual shift mode.

Rice. 13. Schematic diagram of the manual transmission Ford Fusion

1 – a back cover of a case of a transmission; 2 - gearbox housing Ford Fusion; 3 - breather; 4 - the working cylinder of the clutch release hydraulic drive; 5 - clutch housing; 6 - clutch release bearing; 7 - input shaft; 8 - secondary shaft; 9 - main gear and differential

Double-shaft gearbox with five synchronized forward gears. The gearbox and main gear with differential have a common crankcase 2 (Fig. 13).

Clutch housing 5 is attached to the front of the box housing. A stamped steel cover 1 is installed on the rear of the gearbox housing.

On the primary shaft 7 is fixed on the splines of the shaft gear 5th gear with a synchronizer, and the drive gears 1st, 2nd, 3rd and 4th gears are made in one piece with the input shaft.

The output shaft of the Ford Fusion manual transmission is made in one piece with the final drive gear 9.

In addition, the driven gears of I, II, III, IV and V gears freely rotating on plain bearings are installed on the shaft.

The forward gears are switched on by axial movement of the clutches of two synchronizers of I–II and III–IV gears and the synchronizer clutch of the V gear mounted on the secondary shaft. The gearshift mechanism is located inside the gearbox housing on its left side.

The drive for controlling the manual gearbox of the Ford Fusion gearbox consists of a gearshift lever with a ball bearing mounted on the base of the body, two shift and gear selection cables, as well as a mechanism installed in the gearbox housing.

To ensure a clear shifting of gears, the shift lever of the shift mechanism is made in one piece with a massive counterweight.

The gear selection and shift cables are structurally different from each other and are not interchangeable.

The main gear of the manual transmission Ford Fusion is made in the form of a pair of spur gears, matched by noise.

Torque is transmitted from the driven gear of the final drive to the differential and then to the front wheel drives.

The differential is conical, two-satellite. The tightness of the connection of the internal hinges of the front wheel drives with the differential gears is ensured by oil seals.

Removal and installation of the Ford Fusion gearbox

The main malfunctions, for the elimination of which it is necessary to remove the manual transmission from the Ford Fusion car:

- increased (compared to usual) noise;

- Difficulty shifting gears of the Ford Fusion gearbox;

– Spontaneous disengagement or fuzzy engagement of gears;

– Oil leakage through seals and gaskets.

In addition, the gearbox is removed to replace the clutch, flywheel and rear crankshaft oil seal.

Remove the air filter.

Remove the battery tray mounting bracket.

Disconnect the transmission control cables from the gearbox.

Remove the gearshift cover by removing the three bolts securing it.

Drain the oil from the Ford Fusion gearbox. Remove the front wheel drives.

Disconnect the wiring harness connector from the reverse light switch.

Disconnect the pipes from the clutch master cylinder.

Disconnect the plastic pipe holder from the bracket on the Ford Fusion manual transmission.

Turn out two bolts of fastening of wires of weight to a body and take away wires aside.

Turn out a bolt of fastening of the plug of a wire of weight to a transmission case and take a wire aside.

Turn out a bolt of fastening of a case of a transmission to the engine from above at the left.

Unscrew the nut of the stud securing the mounting bracket to the gearbox housing and remove the mounting bracket for fastening pipelines (the coolant supply hose was removed).

Turn out a hairpin of fastening of a case of a transmission to the engine from above on the right and take aside a "mass" wire. Remove the starter.

Support the engine securely or hang it out using a hoist. Install a similar support under the Ford Fusion gearbox.

Remove the left support of the power unit.

Turn out three bolts of fastening of an arm of the left support of the power unit and remove an arm.

Remove the rear support of the power unit.

Remove the four bolts securing the manual transmission to the oil sump.

Turn out a bolt of forward and two bolts of back fastening of a transmission to the engine.

Slide the Ford Fusion gearbox back until the gearbox input shaft comes out of the clutch disc hub. Then move the box as far back as possible, remove the support from under it and, tilting the back of the box down, remove it from the car.

Install the gearbox, all removed parts and assemblies in the reverse order of removal.

Pour oil into the gearbox.

Bleed the air from the hydraulic clutch release.

Removal and installation of the scenes of the Ford Fusion gearbox control lever

Remove the floor tunnel lining.

Pry off the tip of the gear selection cable with a screwdriver and disconnect the tip from the leash.

Disconnect the cable end from the manual transmission control lever in the same way.

Rotate the selector cable stop counterclockwise and remove the sheath stop from the shift lever yoke bracket.

Disconnect the Ford Fusion shift cable sheath retainer in the same way.

Turn out four nuts of hairpins of fastening of scenes of the lever of a gear change to a body, take washers and remove a scene.

Install the parts in the reverse order of removal.

Adjustment of the drive control manual transmission Ford Fusion

The Ford Fusion gearbox control drive consists of two cables: gear selection and shift, however, only the gear selection cable is adjustable.

Set the transmission control lever to the neutral position and fix it by inserting a metal rod with a diameter of 3 mm into the fork of the leash and into the opening of the backstage (this operation is shown on the removed backstage).

Remove the engine crankcase protection (if any).

Remove the Ford Fusion gearshift cover.

Unlock the tip of the gear selection cable by pressing the tip lock button (red) and pull it out of the tip.

Move the gear selector lever all the way up (this also moves the tip up the cable). Measure the length of the threaded part of the cable.

Move the lever all the way down and again measure the length of the threaded part of the cable (the difference between the two measurements is the value of the full stroke of the lever).

Move the lever up halfway up and lock the tip onto the cable by pushing the red button into the tip.

Install the gearshift cover.

Remove the locking rod from the hole in the Ford Fusion gearbox control lever.

Start up the engine and check up clearness of inclusion of all transfers. Repeat the adjustment if necessary.

Install the floor tunnel lining.

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Ford Focus 2

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Ford Focus

Ford Fusion, Fiesta

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