Section 1735 (Manual Transaxle/Transmission): Assembly: Transaxle

WARNING: This page is about a different car, the 2006 Mercury Milan and 2006 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

SPECIAL TOOL(S)

Courtesy of FORD MOTOR CO.	Bell Housing Seal Replacer 308-057 (T77J-7025-G)
Courtesy of FORD MOTOR CO.	Differential Bearing Cup Replacer 308-162 (T88C-77000-EH)
Courtesy of FORD MOTOR CO.	Installer, Halfshaft Oil Seal 308-119 (T87C-77000-H)
Courtesy of FORD MOTOR CO.	Front Hub Bearing Cup 204-039 (T77F-1217-B)
Courtesy of FORD MOTOR CO.	Handle 205-153 (T80T-4000-W)
Courtesy of FORD MOTOR CO.	Holding Fixture 307-003 (T57L-500-B)
Courtesy of FORD MOTOR CO.	Rotating Tool 308-165 (T88C-77000-L)
Courtesy of FORD MOTOR CO.	Shim Selection Set 308-161 (T88C-77000-C)
Courtesy of FORD MOTOR CO.	Shim Selection Tool Set 308-164 (T88C-77000-JF)
Courtesy of FORD MOTOR CO.	Torque Adapter 308-160 (T88C-7025-GH)
Courtesy of FORD MOTOR CO.	Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-A)

MATERIAL

Item	Specification
Silicone Gasket and Sealant TA-30	WSE-M4G323-A4

Fig 1: Identifying Transaxle Components

Courtesy of FORD MOTOR CO.

CAUTION: Whenever the transaxle has been disassembled, the bearing preload must be adjusted. The input shaft, output shaft and differential bearing preload can be adjusted by selecting shims to insert between the bearing races and the case on the case side.

Using the special tool, install the input shaft seal.

Fig 2: Locating Special Tool And Input Shaft Seal
Courtesy of FORD MOTOR CO.
Install the input shaft bearing cup into the flywheel housing.

Fig 3: Locating Input Shaft Bearing Cup Into Flywheel Housing
Courtesy of FORD MOTOR CO.
Install the input shaft.

Fig 4: Locating Input Shaft
Courtesy of FORD MOTOR CO.
Install the bearing cup onto the bearing.

Fig 5: Locating Bearing Cup
Courtesy of FORD MOTOR CO.
Install the special tools.

Fig 6: Identifying Special Tools
Courtesy of FORD MOTOR CO.
Install the transaxle case.
1. Position the transaxle case to the input shaft and the special tools.
2. Install the bolts.
  - Tighten to 45 Nm (33 lb-ft).
    
    Fig 7: Identifying Transaxle Case And Bolts
    Courtesy of FORD MOTOR CO.
Mount the special tool to the transaxle case.

Fig 8: Mounting Special Tool To Transaxle Case
Courtesy of FORD MOTOR CO.
Rotate the input shaft to seat the bearings.
Zero the dial indicator.

Fig 9: Zeroing Dial Indicator
Courtesy of FORD MOTOR CO.

CAUTION: The shaft must be lifted equally on both sides or it may cock to one side, resulting in an incorrect reading.

Rotate the input shaft until the dial indicator returns to zero then raise the input shaft and read the end play.

Take and record 3 readings within 0.10 mm (0.004 in) of each other. Use the formula below to select the correct shim size.

AVERAGE READINGS AND EXAMPLE

Average the 3 readings	Example
Reading A	0.019
Reading B	0.014
Reading C	+0.021 0.05 ÷ 3 = 0.018
Reading C	+0.021 0.05 ÷ 3 = 0.018
Final Shim Size	0.018

Fig 10: Raising Input Shaft

Courtesy of FORD MOTOR CO.

CAUTION: Do not use more than 2 shims.

From the Shim Selection Set, select the shim(s) that is closest to (or slightly thinner than) the final shim size calculated in the previous step.
Remove the transaxle case, special tools, bearing cup, and input shaft.
Install the input shaft shim(s).

Fig 11: Locating Input Shaft Shim
Courtesy of FORD MOTOR CO.
Using the special tools, install the input shaft bearing cup.

Fig 12: Locating Input Shaft Bearing Cup
Courtesy of FORD MOTOR CO.
Install the funnel.

Fig 13: Locating Funnel
Courtesy of FORD MOTOR CO.
Using the special tools, install the output shaft bearing cup.

Fig 14: Locating Output Shaft Bearing Cup
Courtesy of FORD MOTOR CO.
Install the output shaft.

Fig 15: Locating Output Shaft
Courtesy of FORD MOTOR CO.
Install the bearing cup onto the bearing.

Fig 16: Locating Bearing Cup Onto Bearing
Courtesy of FORD MOTOR CO.

NOTE: The gauge halves must be turned to eliminate any gap between them.

Fig 17: Identifying Special Tools

Courtesy of FORD MOTOR CO.

Install the special tools.
Install the transaxle case.
1. Position the transaxle case to the output shaft and the special tools.
2. Install the bolts.
  - Tighten to 45 Nm (33 lb-ft).
    
    Fig 18: Identifying Transaxle Case To Output Shaft And Bolts
    Courtesy of FORD MOTOR CO.
Mount the special tools on the transaxle case.

Fig 19: Mounting Special Tools On Transaxle Case
Courtesy of FORD MOTOR CO.
Rotate the output shaft to seat the bearings.
Zero the dial indicator.

Fig 20: Locating Dial Indicator
Courtesy of FORD MOTOR CO.

CAUTION: The shaft must be lifted equally on both sides or it may cock to one side, resulting in an incorrect reading.

Rotate the output shaft until the dial indicator returns to zero then raise the output shaft and read the end play.

Take and record 3 readings within 0.10 mm (0.004 in) of each other. Use the formula below to select the correct shim size.

AVERAGE READINGS AND EXAMPLE

Average the 3 readings	Example
Reading A	0.019
Reading B	0.014
Reading C	+0.021 0.054 ÷ 3 = 0.018
Final Shim Size	0.018

Fig 21: Raising Output Shaft

Courtesy of FORD MOTOR CO.

CAUTION: Do not use more than 2 shims.

From the Shim Selection Set, select the shim(s) that is closest to (or slightly thinner than) the final shim size determined in the previous step.
Remove the transaxle case, special tools, bearing cup and output shaft.
Install the shim.

Fig 22: Locating Shim
Courtesy of FORD MOTOR CO.
Using the special tools, install the output shaft bearing cup.

Fig 23: Locating Special Tools And Output Shaft Bearing Cup
Courtesy of FORD MOTOR CO.
Using the special tools, install the differential bearing cup into the flywheel housing.

Fig 24: Locating Special Tools And Differential Bearing Cup
Courtesy of FORD MOTOR CO.
Install the differential.

Fig 25: Locating Differential
Courtesy of FORD MOTOR CO.
Install the bearing cup onto the bearing.

Fig 26: Locating Bearing Cup
Courtesy of FORD MOTOR CO.

NOTE: The gauge halves must be turned to eliminate any gap between them.

Fig 27: Identifying Special Tools

Courtesy of FORD MOTOR CO.

Install the special tools.
Install the transaxle case.
1. Position the transaxle case to the differential and the special tools.
2. Install the bolts.
  - Tighten to 45 Nm (33 lb-ft).
    
    Fig 28: Identifying Transaxle Case And Bolts
    Courtesy of FORD MOTOR CO.
Using the special tool, adjust gauge until the free play is removed. Turn gauge back together.

Fig 29: Identifying Special Tool
Courtesy of FORD MOTOR CO.
Insert the special tool through the transaxle case and engage the differential pinion shaft.

Fig 30: Identifying Special Tool
Courtesy of FORD MOTOR CO.
Using the special tools, adjust gauge until the differential rotation is within specification.

Fig 31: Special Tool With Torque Specification
Courtesy of FORD MOTOR CO.
Measure the gap in the special tool.

Fig 32: Locating Gap In Special Tool
Courtesy of FORD MOTOR CO.

CAUTION: Do not use more than 2 differential shims.

Add 0.15 mm (0.0059 in) to the measurement to achieve the final clearance.

Using the following chart, select the differential bearing shims that are closest to (or slightly larger than) the final shim size.

THICKNESS SPECIFICATION

Shim Thickness
0.10 mm (0.004 in)
0.15 mm (0.006 in)
0.20 mm (0.008 in)
0.25 mm (0.010 in)
0.30 mm (0.012 in)
0.35 mm (0.014 in)
0.40 mm (0.016 in)
0.45 mm (0.018 in)
0.50 mm (0.020 in)
0.55 mm (0.022 in)
0.60 mm (0.024 in)
0.65 mm (0.026 in)
0.70 mm (0.028 in)
0.75 mm (0.030 in)
0.80 mm (0.032 in)
0.85 mm (0.034 in)
0.90 mm (0.036 in)
0.95 mm (0.038 in)
1.00 mm (0.040 in)
1.05 mm (0.042 in)
1.10 mm (0.044 in)
1.15 mm (0.046 in)
1.20 mm (0.048 in)

Remove the transaxle case, special tools, bearing cup and differential.
Install the differential bearing cup shim(s) into the transaxle case.

Fig 33: Locating Differential Bearing Cup Shims Into Transaxle Case
Courtesy of FORD MOTOR CO.
Using the special tools, install the differential bearing cup into the transaxle case.

Fig 34: Locating Special Tools And Differential Bearing Cup
Courtesy of FORD MOTOR CO.

NOTE: Transaxle case side shown, flywheel housing side similar.

Fig 35: Identifying Special Tool

Courtesy of FORD MOTOR CO.

Using the special tool, install the halfshaft seals.
Install the output shaft, the input shaft and the differential together.

Fig 36: Locating Output And Input Shaft
Courtesy of FORD MOTOR CO.
Install the reverse lever and the reverse lever shaft.

Fig 37: Locating Reverse Lever And Reverse Lever Shaft
Courtesy of FORD MOTOR CO.
Install the reverse lever roll pin.

Fig 38: Locating Reverse Lever Roll Pin
Courtesy of FORD MOTOR CO.
Install the spring and the shift detent.

Fig 39: Locating Spring And Shift Detent
Courtesy of FORD MOTOR CO.
Shift the synchronizers into the 2nd and 4th gear positions.
Install the gear shifter fork and main shift control shaft assembly.
- Rotate the shaft clockwise, disengaging the shift finger from the shift fork. Pull the rail upward and insert the shift rail into the rail bore. Depress the detent and rotate the shift assembly into position.
  
  Fig 40: Installing Gear Shifter Fork And Main Shift Control Shaft Assembly
  Courtesy of FORD MOTOR CO.
Install the shift fork selector lever.
1. Install the shift fork selector lever.
2. Install the shift lever shaft.
  - Position the shift fork selector lever socket(s) to the main shift control shaft pivot ball and the change shaft.
    
    Fig 41: Identifying Shift Fork Selector Lever And Shift Lever Shaft
    Courtesy of FORD MOTOR CO.
Install the shift lever shaft pin.
- Shift lever shaft uses a solid pin.
- Use a screwdriver to aid installation.
  
  Fig 42: Locating Shift Lever Shaft Pin
  Courtesy of FORD MOTOR CO.
Install the shift control shaft and shift gate.
1. Install the shift gate.
2. Install the shift control shaft.
3. Install the shift gate bolt.
  - Make sure to align the shift gate at the bottom and the shift gate with the main shift control.
  - Tighten to 13 Nm (10 lb-ft).
    
    Fig 43: Identifying Shift Gate, Bolt And Shift Control Shaft
    Courtesy of FORD MOTOR CO.
Install the reverse idler gear and reverse idler gear shaft.

Fig 44: Locating Reverse Idler Gear And Reverse Idler Gear Shaft
Courtesy of FORD MOTOR CO.
Install the magnet.

Fig 45: Locating Magnet
Courtesy of FORD MOTOR CO.
Align the end of the gear selector interlock sleeve with the gear selector arm. The reverse idler gear shaft hole should face outward. Position the gear selector arm and reverse idler gear shaft.
Position the 2nd and 4th gear synchronizers into NEUTRAL, then shift 1st/2nd gear synchronizer into 1st gear.
Install the oil funnel.

CAUTION: The transaxle case must be installed within 4 minutes after applying silicone gasket and sealant.

Apply a small bead of silicone gasket and sealant to the transaxle mating surface.
Install the transaxle case and the 2 transaxle case bolts.
- Make sure to align the shift lever to the shift lever shaft. Do not move the shaft outward to the stop. The washer can slide off of the shaft into the case.
- Tighten to 45 Nm (33 lb-ft).
  
  Fig 46: Locating Transaxle Mating Surface
  Courtesy of FORD MOTOR CO.

CAUTION: Make sure that the shift rail guide bolt is in the groove of the shift rail.

CAUTION: Do not shift the transaxle until the bolts are installed.

Position the bolts into the transaxle case.
1. Install the reverse idler shaft bolt.
2. Install the shift rail guide bolt.
  - Tighten the reverse idler shaft bolt to 22 Nm (16 lb-ft).
  - Tighten the shift rail guide bolts to 12 Nm (9 lb-ft).
    
    Fig 47: Identifying Reverse Idler Shaft Bolt And Shift Rail Guide Bolt
    Courtesy of FORD MOTOR CO.
Check the shift function.
Install the remaining 13 transaxle case bolts.
- Tighten to 45 Nm (33 lb-ft).
  
  Fig 48: Locating Transaxle Case Bolts
  Courtesy of FORD MOTOR CO.
Install the shift lock bolt, spring and ball.
- Tighten to 18 Nm (13 lb-ft).
  
  Fig 49: Identifying Shift Lock Bolt, Spring And Ball
  Courtesy of FORD MOTOR CO.
Install the shift lever assembly.
- Tighten to 22 Nm (16 lb-ft).
Install 5th gear.

Fig 50: Locating 5Th Gear
Courtesy of FORD MOTOR CO.
Install the 5th gear bushing.

Fig 51: Locating 5Th Gear Bushing
Courtesy of FORD MOTOR CO.
Install the 5th speed cluster gear.

Fig 52: Locating 5Th Speed Cluster Gear
Courtesy of FORD MOTOR CO.
Install the reverse/5th shift fork and synchronizer hub as an assembly.

Fig 53: Identifying Reverse/5Th Shift Fork And Synchronizer Hub Assembly
Courtesy of FORD MOTOR CO.
Install a new reverse/5th shift fork roll pin.

CAUTION: Do not reuse locknuts.

CAUTION: Stake the locknuts.

Use the special tool 308-160, to keep the input shaft from turning. Install new input and output shaft locknuts. Stake the locknuts.
- Tighten to 160 Nm (118 lb-ft).
  
  Fig 54: Locating Input And Output Shaft Locknuts
  Courtesy of FORD MOTOR CO.

CAUTION: The case cover must be installed within 4 minutes after applying silicone gasket and sealant.

Apply a small bead of silicone gasket and sealant to the case and cover mating surface.
Install the 9 case cover bolts and the case covers.

Fig 55: Locating Case Cover Bolts
Courtesy of FORD MOTOR CO.
Install the anchor bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 56: Locating Anchor Bolt
  Courtesy of FORD MOTOR CO.
Install the clutch release fork and bearing.
1. Install the boot.
2. Install the clutch release fork and bearing.
  
  Fig 57: Identifying Boot, Clutch Release Fork And Bearing
  Courtesy of FORD MOTOR CO.
Remove the transaxle from the special tool.

Fig 58: Identifying Special Tool And Transaxle
Courtesy of FORD MOTOR CO.