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Manual Transmission — Vehicles With: 6-Speed Manual Transmission 308-03B-1 - MT82 308-03B-1 SECTION 308-03B Manual Transmission — Vehicles With: 6-Speed Manual Transmission - MT82 VEHICLE APPLICATION: 2011.50 Ranger CONTENTS PAGE SPECIFICATIONS Specifications 308-03B-3 DESCRIPTION AND OPERATION Manual Transmission (Overview) 308-03B-4 Component Location 308-03B-4 Overview 308-03B-5 Internal gearshift mechanism 308-03B-6 Internal gears - Transfer case 308-03B-8 (4x2) 308-03B-8 Side view - right-hand side 308-03B-9 4x4 308-03B-10 Side view - left-hand side 308-03B-10 Side view - right-hand side 308-03B-11 Torque path 308-03B-12 External gearshift mechanism 308-03B-15 DIAGNOSIS AND TESTING Manual Transmission 308-03B-16 GENERAL PROCEDURES Transmission Draining and Filling Transmission Fluid Level Check 308-03B-17 308-03B-18 REMOVAL AND INSTALLATION Input Shaft Seal Output Shaft Seal 308-03B-20 308-03B-21 REMOVAL Transmission — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, 2WD Transmission — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, 4WD 308-03B-24 308-03B-29 DISASSEMBLY Transmission 308-03B-35 Manual Transmission — Vehicles With: 6-Speed Manual Transmission 308-03B-2 - MT82 308-03B-2 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Synchronizers 308-03B-47 ASSEMBLY Transmission 308-03B-49 INSTALLATION Transmission — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, 2WD Transmission — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, 4WD 308-03B-67 308-03B-73 Manual Transmission — Vehicles With: 6-Speed Manual Transmission 308-03B-3 308-03B-3 - MT82 SPECIFICATIONS Lubricants, Fluids, Sealers and Adhesives Item Specification Manual transmission fluid WSD-M2C200-D2 Thread locking compound WSK-M2G349-A7 Sealant WSS-M2G348-A10 Grease ESD-M1C220-A Capacities Litres MT82 transmission - Service fill 2.6 MT82 transmission - Add-on for initial fill or if transmission has been disassembled and assembled in the workshop 0.1 Torque Specifications Description Nm lb-ft lb-in Transmission retaining bolts 50 37 - Reversing lamp switch 20 15 - Transmission output shaft flange retaining nut 200 148 - Oil drain plug 50 37 - Oil fill plug 35 26 - Vehicle speed sensor (VSS) 10 - 89 2011.50 Ranger G1449088en Manual Transmission — Vehicles With: 6-Speed Manual Transmission 308-03B-4 308-03B-4 - MT82 DESCRIPTION AND OPERATION Manual Transmission – Overview Component Location 4x2 Item Description Item Description MT82 4x2 Rear propeller shaft Manual gear change lever Rear drive axle 2011.50 Ranger G1273743en Manual Transmission — Vehicles With: 6-Speed Manual Transmission 308-03B-5 308-03B-5 - MT82 DESCRIPTION AND OPERATION 4x4 Item Description Item Description Front half shafts Rear drive axle MT82 4x4 Transfer case Manual gear change lever Front propeller shaft Rear propeller shaft Front differential assembly Overview The name of the 6-speed manual transaxle MT82 is derived from the distance between the two shafts in the transaxle: 2011.50 Ranger • M stands for Manual • T stands for Transaxle • 82 is the distance between the two shafts in mm G1273743en Manual Transmission — Vehicles With: 6-Speed Manual Transmission 308-03B-6 - MT82 308-03B-6 DESCRIPTION AND OPERATION Transaxles are designed for a torque of max 480 Nm In order to ensure secure mounting of the selector rods, these are passed through a centre bearing mounting plate The centre bearing mounting plate is in turn bolted to the housing All gear selector forks and shift forks are made of forged steel 2011.50 Ranger The sliding elements of the selector forks are made of a plastic material that exhibits high resistance to wear The main selector shaft is mounted in the center bearing mounting plate Internal gearshift mechanism G1273743en Manual Transmission — Vehicles With: 6-Speed Manual Transmission 308-03B-7 308-03B-7 - MT82 DESCRIPTION AND OPERATION Item Description Item Description Selector rod detent 1st/2nd gear selector fork Shift fork bolt Shift fork 1st/2nd gear selector rod Main shift rod Reverse gear selector rod 5th/6th gear selector rod Center bearing mounting plate 10 3rd/4th gear selector rod 2011.50 Ranger G1273743en Manual Transmission — Vehicles With: 6-Speed Manual Transmission 308-03B-8 - MT82 308-03B-8 DESCRIPTION AND OPERATION Internal gears - Transfer case Item Description Right-angle drive Idle gear (4x2) 2011.50 Ranger G1273743en Manual Transmission — Vehicles With: 6-Speed Manual Transmission 308-03B-9 308-03B-9 - MT82 DESCRIPTION AND OPERATION Side view - left-hand side Item Description Item Description Transaxle breather Reverse switch Selector rod detents Reverse gear mounting retaining bolt Shift fork bolts The reverse idler gear shaft is attached to the housing using the reverse gear mounting retaining bolt (4) This should not be mixed up with any other bolt on the transaxle NOTE: The reverse gear mounting retaining bolt should only be removed to dismantle the transaxle Side view - right-hand side 2011.50 Ranger G1273743en Manual Transmission — Vehicles With: 6-Speed Manual Transmission 308-03B-10 308-03B-10 - MT82 DESCRIPTION AND OPERATION Item Description Item Description Shift fork bolts Vehicle speed sensor Selector rod detents Oil drain plug Oil filler plug / oil level check The transmission oil in the MT82 6-speed transaxle does not need to be changed in service Only before repair work on the transaxle should the transmission oil be drained by removing the oil drain plug (4) NOTE: The shift fork bolts (1) must only be removed during repair 2011.50 Ranger The oil filler plug (5) also allows the oil level to be checked 4x4 Side view - left-hand side G1273743en