The disengagement of 1st and 2nd gears in Ford vehicles

On this occasion, we are going to describe a fault that affects diesel models from the FORD manufacturer, specifically a fault detected in the gearbox and that affects the first and second gears of the MMT6 and VMT6 gearboxes.

AFFECTED MODELS

The affected models are:

• FORD MONDEO MKIV Manufactured from 2011 with gearbox MMT6.
• FORD S-MAX Manufactured from 2011 with gearbox MMT6.
• FORD C-MAX Manufactured from 2011 with gearbox MMT6.
• FORD FOCUS Manufactured from 2011 with gearbox MMT6.
• FORD KUGA Manufactured from 2011 with gearbox MMT6.
• FORD KUGA MKII Manufactured from 2011 with gearbox MMT6.
• FORD TRANSIT Manufactured from 2011 with gearbox VMT6.
• FORD TRANSIT MKVI Manufactured from 2011 with gearbox VMT6.

SYMPTOM

1st and 2nd gear disengage without warning and selection from the driver

CAUSE

The cause of this fault is the excessive clearance in the synchronizer assembly for the 1st and 2nd gears.

Gear Box MMT6

REMEDY

The repair procedure involves following the steps below:

1. Remove the gearbox.
2. Remove the clutch slave cylinder.
3. Thoroughly clean the gearbox housing.
4. Remove the gearbox housing and the forks.
5. Check the condition of the differential.
6. Remove the input and output shaft assembly.
7. Renew the 1st and 2nd gear and the 1st and 2nd gear synchronizer assembly.
8. Calculate the thickness of the shim necessary to eliminate excessive clearance.
9. Replace the affected bearings.
10. Renew all the gaskets.
11. Assemble the components in the reverse order to dismantling.
12. Ensure the gearbox is refilled with the correct grade and quantity of oil

Once reassembly is complete carry out the corresponding checks to confirm that the gearbox functions correctly.

The following reference/part numbers to ensure and effective repair are:

Reference/part number for the repair kit for the 1st and 2nd gear synchronizer assembly......................1 852 724.