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

G04682134Courtesy of FORD MOTOR CO.
 Holding Fixture
307-003 (T57L-500-B)
G04682135Courtesy of FORD MOTOR CO.
 Torque Adapter
308-160 (T88C-7025-GH)
  1. Clean the transaxle exterior with solvent before disassembly.
    2. WARNING: Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes. Wear protective eye wear whenever using compressed air. Failure to follow these instructions may result in personal injury.
  2. Clean all removed parts and all sealing surfaces with solvent, and dry with compressed air.
  3. Clean out all holes and passages with compressed air and verify that there are no obstructions.
  4. Mount the transaxle to the special tool.
    Fig 1: Locating Transaxle To Special Tool
    G04682136Courtesy of FORD MOTOR CO.
  5. Remove the drain plug and drain the transaxle.
  6. Remove the clutch release fork and bearing.
    1. Remove the boot.
    2. Remove the clutch release fork and bearing.
      Fig 2: Identifying Boot, Clutch Release Fork And Bearing
      G04682137Courtesy of FORD MOTOR CO.
  7. Remove the anchor bolt.
    Fig 3: Locating Anchor Bolt
    G04682138Courtesy of FORD MOTOR CO.
  8. Remove the bolt and the vehicle speed sensor (VSS).
    Fig 4: Locating Vehicle Speed Sensor (VSS) Bolt
    G04682139Courtesy of FORD MOTOR CO.
  9. Rotate the transaxle 180 degrees.
  10. Remove the reversing lamp switch.
    Fig 5: Locating Reversing Lamp Switch
    G04682140Courtesy of FORD MOTOR CO.
  11. Shift the transaxle into the NEUTRAL position.
  12. Remove the 9 case cover bolts and the case cover.
    Fig 6: Locating Case Cover Bolts
    G04682141Courtesy of FORD MOTOR CO.
    13. CAUTION: Do not reuse locknuts.
  13. Remove the input and output shaft locknuts.
    1. Using the special tool, keep the input shaft from turning.
    2. Remove and discard the input and output shaft locknuts.
      • Using a punch, release the locking tabs from the shafts.
        Fig 7: Identifying Special Tool And Input & Output Shaft Locknuts
        G04682142Courtesy of FORD MOTOR CO.
  14. Remove and discard the reverse/5th shift fork roll pin.
    Fig 8: Locating Reverse/5Th Shift Fork Roll Pin
    G04682143Courtesy of FORD MOTOR CO.
  15. Remove the reverse/5th shift fork and synchronizer hub assembly.
    Fig 9: Locating Reverse/5Th Shift Fork And Synchronizer Hub Assembly
    G04682144Courtesy of FORD MOTOR CO.
  16. Remove the synchronizer blocking ring.
    Fig 10: Locating Synchronizer Blocking Ring
    G04682145Courtesy of FORD MOTOR CO.
  17. Remove the 5th speed cluster gear.
    Fig 11: Locating 5Th Speed Cluster Gear
    G04682146Courtesy of FORD MOTOR CO.
  18. Remove the 5th gear bushing.
    Fig 12: Locating 5Th Gear Bushing
    G04682147Courtesy of FORD MOTOR CO.
  19. Remove the 5th speed gear.
    Fig 13: Locating 5Th Speed Gear
    G04682148Courtesy of FORD MOTOR CO.
  20. Remove the reverse idler shaft lock bolt and shift rail guide bolt.
    Fig 14: Locating Reverse Idler Shaft Lock Bolt And Shift Rail Guide Bolt
    G04682149Courtesy of FORD MOTOR CO.
  21. Remove the bolt, spring and ball.
    Fig 15: Identifying Bolt, Spring And Ball
    G04682150Courtesy of FORD MOTOR CO.
  22. Remove the 15 transaxle case bolts and separate the transaxle case.
    • After separating the transaxle cases, position the removed case on its side.
  23. Remove the funnel bolt and the funnel.
    Fig 16: Locating Funnel
    G04682151Courtesy of FORD MOTOR CO.
  24. Remove the magnet.
    Fig 17: Locating Magnet
    G04682152Courtesy of FORD MOTOR CO.
  25. Remove the reverse idler gear and the reverse idler gear shaft.
    Fig 18: Locating Reverse Idler Gear
    G04682153Courtesy of FORD MOTOR CO.
  26. Remove the shift gate bolt.
    Fig 19: Locating Shift Gate Bolt
    G04682154Courtesy of FORD MOTOR CO.
  27. Remove the shift control shaft and shift gate.
    1. Remove the shift control shaft.
    2. Remove the shift gate.
      Fig 20: Identifying Shift Control Shaft And Shift Gate
      G04682155Courtesy of FORD MOTOR CO.
  28. Remove the shift lever shaft roll pin, then remove the shift lever shaft and shift fork selector lever.
    • Use a screwdriver to aid removal.
      Fig 21: Locating Shift Lever Shaft Roll Pin
      G04682156Courtesy of FORD MOTOR CO.
  29. Move the shift forks upward into 2nd and 4th gears.
    Fig 22: Moving Shift Forks Upward Into 2Nd And 4Th Gears
    G04682157Courtesy of FORD MOTOR CO.
  30. Remove the gear shifter fork and main shift control shaft assembly.
    • Lift the rail out of the rail pocket.
      Fig 23: Locating Main Shift Control Shaft Assembly
      G04682158Courtesy of FORD MOTOR CO.
  31. Remove the shift detent and spring.
    Fig 24: Locating Spring
    G04682159Courtesy of FORD MOTOR CO.
  32. Remove the shift lever roll pin.
    Fig 25: Locating Shift Lever Roll Pin
    G04682160Courtesy of FORD MOTOR CO.
  33. Remove the reverse shift lever shaft and the reverse lever.
    Fig 26: Locating Reverse Shift Lever Shaft And Reverse Lever
    G04682161Courtesy of FORD MOTOR CO.
  34. Remove the output and input shafts as an assembly.
    Fig 27: Locating Output And Input Shafts Assembly
    G04682162Courtesy of FORD MOTOR CO.
  35. Remove the differential.
    Fig 28: Locating Differential
    G04682163Courtesy of FORD MOTOR CO.
  36. For further disassembly of the transaxle case, refer to TRANSAXLE CASE .
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