Section 2680 (Manual Transaxle): Assembly: Transaxle: Material

WARNING: This page is about a different car, the 2011 Mercury Milan and 2011 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

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

Fig 1: Exploded View Of Transaxle Components

Courtesy of FORD MOTOR CO.

Item	Part Number	Description
1	7505	Clutch housing
2	-	Control rod
3	-	Control end
4	-	1st/2nd shift fork
5	-	Control lever
6	-	Interlock lever
7	-	3rd/4th shift fork
8	-	Inner shift lever
9	-	Spring pin
10	-	Push pin component and spring
11	4026	Differential
12	-	Secondary shaft gear assembly
13	-	Primary shaft gear assembly
14	-	Shift fork and shift rod assembly
15	-	Reverse idler gear
16	-	Reverse shift fork
17	-	5th/reverse shift rod end
18	-	5th/reverse shift rod
19	7L027	Magnet
20	7F116	Crank lever component
21	-	O-ring
22	7C355	Crank lever shaft
23	-	Pin
24	7005	Transaxle case component
25	7G072	Neutral switch
26	-	Push pin component
27	-	Detent spring
28	-	Detent spring bolt and washer
29	15520	Reversing lamp switch
30	-	Lock bolt
31	-	Shift rail guide bolt
32	-	Reverse idler shaft lock bolt
33	-	Clutch hub
34	-	Clutch hub sleeve
35	-	Secondary 5th gear
36	-	Spacer
37	-	Gear sleeve
38	-	5th gear
39	-	5th gear synchronizer
40	-	Synchronizer key spring
41	-	5th/6th clutch hub
42	-	5th/6th shift fork
43	-	Secondary 6th gear
44	-	Synchronizer key spring
45	-	6th gear synchronizer
46	-	6th gear
47	-	Gear sleeve
48	-	Bearing (secondary shaft)
49	-	Bearing (primary shaft)
50	7N170	Locknut (secondary shaft)
51	7N170	Locknut (primary shaft)
52	7222	Rear cover

NOTE: 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.

Install the input shaft.

Fig 2: Locating Input Shaft
Courtesy of FORD MOTOR CO.
Install the bearing cup onto the bearing.

Fig 3: Locating Bearing Cup
Courtesy of FORD MOTOR CO.
Install the Shim Selection Set.

Fig 4: Installing Shim Selection Set
Courtesy of FORD MOTOR CO.
Install the transaxle case.
1. Position the transaxle case in place.
2. Install the Shim Selection Set bolts.
  - Tighten to 45 Nm (33 lb-ft).
  Fig 5: Positioning Transaxle Case
  Courtesy of FORD MOTOR CO.
Mount the Dial Indicator Gauge with Holding Fixture to the transaxle case.

Fig 6: Mounting Dial Indicator Gauge With Holding Fixture To Transaxle Case
Courtesy of FORD MOTOR CO.
Rotate the input shaft to seat the bearings.
Zero the Dial Indicator Gauge with Holding Fixture.

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

Fig 7: Raising Input Shaft

Courtesy of FORD MOTOR CO.

Rotate the input shaft until the Dial Indicator Gauge returns to zero, then raise the input shaft and read the end play.

Take and record 3 readings within 0.10 mm (0.003 in) of each other. Use the formula below to select the correct shim size.

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

NOTE: 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, Shim Selection Set, bearing cup and input shaft.
Install the input shaft shim(s).

Fig 8: Locating Input Shaft Shim
Courtesy of FORD MOTOR CO.
Install the input shaft bearing cup.

Fig 9: Locating Input Shaft Bearing Cup
Courtesy of FORD MOTOR CO.
Install the funnel and the output shaft bearing cup.

Fig 10: Locating Output Shaft Bearing Cup And Funnel
Courtesy of FORD MOTOR CO.
Install the output shaft.

Fig 11: Locating Output Shaft
Courtesy of FORD MOTOR CO.
Install the bearing cup onto the bearing.

Fig 12: Locating Bearing Cup
Courtesy of FORD MOTOR CO.

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

Fig 13: Installing Shim Selection Set

Courtesy of FORD MOTOR CO.

Install the Shim Selection Set.
Install the transaxle case.
1. Position the transaxle case in place.
2. Install the Shim Selection Set bolts.
  - Tighten to 45 Nm (33 lb-ft).
Fig 14: Positioning Transaxle Case
Courtesy of FORD MOTOR CO.
Mount the Dial Indicator Gauge with Holding Fixture on the transaxle case.

Fig 15: Mounting Dial Indicator Gauge With Holding Fixture On Transaxle Case
Courtesy of FORD MOTOR CO.
Rotate the output shaft to seat the bearings.
Zero the Dial Indicator Gauge.

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

Fig 16: Raising Input Shaft

Courtesy of FORD MOTOR CO.

Rotate the output shaft until the Dial Indicator Gauge returns to zero, then raise the output shaft and read the end play.

Take and record 3 readings within 0.10 mm (0.003 in) of each other. Use the formula below to select the correct shim size.

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

NOTE: 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, Shim Selection Set, bearing cup and output shaft.
Install the shim.

Fig 17: Locating Transaxle Case Shim
Courtesy of FORD MOTOR CO.
Install the funnel and the output shaft bearing cup.

Fig 18: Locating Output Shaft Bearing Cup And Funnel
Courtesy of FORD MOTOR CO.
Install the differential.

Fig 19: Locating Differential
Courtesy of FORD MOTOR CO.
Install the bearing cup onto the bearing.

Fig 20: Locating Bearing Cup
Courtesy of FORD MOTOR CO.

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

Fig 21: Installing Shim Selection Set

Courtesy of FORD MOTOR CO.

Install the Shim Selection Set.
Install the transaxle case.
1. Position the transaxle case in place.
2. Install the Shim Selection Set bolts.
- Tighten to 45 Nm (33 lb-ft).
Fig 22: Positioning Transaxle Case
Courtesy of FORD MOTOR CO.
Using the Shim Selection Set, adjust gauge until the free play is removed. Turn gauge back together.

Fig 23: Adjusting Gauge Using Shim Selection Set
Courtesy of FORD MOTOR CO.
Insert the Differential Rotator through the transaxle case and engage the differential pinion shaft.

Fig 24: Engaging Differential Pinion Shaft
Courtesy of FORD MOTOR CO.
Using the Differential Rotator and Shim Selector Set, adjust gauge until the differential rotation is within specification.

Fig 25: Adjusting Gauge Using Differential Rotator And Shim Selector Set With Torque Specifications
Courtesy of FORD MOTOR CO.
Measure the gap in the Shim Selector Set.

Fig 26: Locating Shim Selector Set
Courtesy of FORD MOTOR CO.

NOTE: Do not use more than 2 differential shims.

Add 0.15 mm (0.005 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.

Shim Thickness
0.10 mm (0.003 in)
0.15 mm (0.005 in)
0.20 mm (0.007 in)
0.25 mm (0.009 in)
0.30 mm (0.011 in)
0.35 mm (0.013 in)
0.40 mm (0.015 in)
0.45 mm (0.017 in)
0.50 mm (0.019 in)
0.55 mm (0.021 in)
0.60 mm (0.023 in)
0.65 mm (0.025 in)
0.70 mm (0.027 in)
0.75 mm (0.029 in)
0.80 mm (0.031 in)
0.85 mm (0.033 in)
0.90 mm (0.035 in)
0.95 mm (0.037 in)
1.00 mm (0.039 in)
1.05 mm (0.041 in)
1.10 mm (0.043 in)
1.15 mm (0.045 in)
1.20 mm (0.047 in)

Remove the transaxle case, Shim Selection Set, differential and bearing cup.
Install the differential bearing cup shim(s) into the transaxle case.

Fig 27: Locating Differential Bearing Cup Shim
Courtesy of FORD MOTOR CO.
Using the Differential Bearing Cup Installer and Handle, install the differential bearing cup into the transaxle case.

Fig 28: Installing Differential Bearing Cup Into Transaxle Case Using Differential Bearing Cup Installer And Handle
Courtesy of FORD MOTOR CO.
Install the output shaft, the input shaft and the differential together.

Fig 29: Installing Output Shaft, Input Shaft And Differential
Courtesy of FORD MOTOR CO.
Install the spring and the shift detent.

Fig 30: Installing Spring And Shift Detent
Courtesy of FORD MOTOR CO.
Shift the synchronizers into the 2nd and 4th gear positions.
Install the main shift control shaft assembly, shift forks.

Fig 31: Locating Main Shift Control Shaft Assembly And Shift Forks
Courtesy of FORD MOTOR CO.

NOTE: Align the reverse idler shaft anchor bolt hole for installation of the bolt through the case.

Fig 32: Locating Reverse Idler Gear Assembly

Courtesy of FORD MOTOR CO.

Install the reverse idler gear and shift fork.
Install the shift control shaft and the shift gate.

Fig 33: Locating Shift Control Shaft
Courtesy of FORD MOTOR CO.

NOTE: Make sure to align the shift gate at the bottom and the shift gate with the main shift control.

Fig 34: Locating Shift Gate Bolt

Courtesy of FORD MOTOR CO.

Install the shift gate bolt.
- Tighten to 13 Nm (115 lb-in).

NOTE: Shift lever shaft uses a solid pin.

Fig 35: Locating Shift Lever Shaft Pin, Shift Lever Shaft And Shift Fork Selector Lever

Courtesy of FORD MOTOR CO.

Install the shift lever shaft, shift fork selector lever and shift shaft pin.
Install the magnet.

Fig 36: Locating Magnet
Courtesy of FORD MOTOR CO.
Position the 2nd and 4th gear synchronizers into neutral, then shift the 1st/2nd gear synchronizer into neutral.
Install the oil funnel.

Fig 37: Locating Funnel
Courtesy of FORD MOTOR CO.

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

Fig 38: Locating Transaxle Case Bolts

Courtesy of FORD MOTOR CO.

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).
Install the shift detent ball, spring and bolt.
- Tighten to 18 Nm (159 lb-in).
Fig 39: Locating Shift Detent Bolt
Courtesy of FORD MOTOR CO.

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

NOTE: Do not shift the transaxle until the reverse idler shaft lock bolt and the shift rail guide bolt are installed.

Fig 40: Identifying Shift Rail Guide Bolts

Courtesy of FORD MOTOR CO.

Install the reverse idler shaft lock bolt and the shift rail guide bolt.
1. Install the reverse idler shaft lock bolt.
  - Tighten the reverse idler shaft lock bolt to 22 Nm (16 lb-ft).
2. Install the shift rail guide bolt.
- Tighten the shift rail guide bolt to 12 Nm (106 lb-in).
Check the shift function.
Install the remaining 13 transaxle case bolts.
- Tighten to 45 Nm (33 lb-ft).
Install the primary and secondary 5th gears.

Fig 41: Locating 5th Speed Primary And Secondary Gears
Courtesy of FORD MOTOR CO.
Install the spacer and the gear sleeve.

Fig 42: Locating Spacer And Gear Sleeve
Courtesy of FORD MOTOR CO.
Install the 5th/6th shift fork and synchronizer assembly.

Fig 43: Locating 5th/6th Shift Fork And Synchronizer Assembly
Courtesy of FORD MOTOR CO.
Install the gear spacer.

Fig 44: Locating Gear Sleeve
Courtesy of FORD MOTOR CO.
Install the primary and secondary 6th gears.

Fig 45: Locating Primary And Secondary 6th Gears
Courtesy of FORD MOTOR CO.

NOTE: When the locknuts are tightened to specifications they will seat the bearings.

Fig 46: Locating Primary And Secondary Shafts 6th Gear Bearings

Courtesy of FORD MOTOR CO.

Install the 6th gear bearings onto the primary and secondary shafts.
Shift the 5th/6th gear shift fork to 5th.

Fig 47: Locating 5th/6th Gear Shift Fork
Courtesy of FORD MOTOR CO.

NOTE: Do not reuse locknuts.

Fig 48: Identifying Locking Tabs

Courtesy of FORD MOTOR CO.

Install the new primary and secondary shaft locknuts.
1. Shifting into 5th/6th gears and using the Transmission Turning Torque Socket will keep the primary shaft from turning.
2. Install the new primary and secondary shaft locknuts. Using a punch, stake the locknuts to the shafts.
- Tighten to 160 Nm (118 lb-ft).

NOTE: Shift 5th/6th into neutral.

Fig 49: Locating 5th/6th Gear Shift Fork Roll Pin

Courtesy of FORD MOTOR CO.

Install a new 5th/6th shift fork roll pin.

NOTE: 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 case cover mating surface.
Install the case cover and the 9 case cover bolts.
- Tighten to 45 Nm (33 lb-ft).
Fig 50: Locating Case Cover Mounting Bolts
Courtesy of FORD MOTOR CO.
If removed, install the anchor bolt.
- Tighten to 10 Nm (89 lb-in).
Fig 51: Locating Anchor Bolt
Courtesy of FORD MOTOR CO.
Install the clutch release fork and bearing.
1. Install the clutch release fork and diaphragm.
2. Install the clutch release bearing.
Fig 52: Identifying Clutch Release Fork And Bearing
Courtesy of FORD MOTOR CO.
Remove the transaxle from the Holding Fixture.

Fig 53: Mounting Transaxle To Holding Fixture
Courtesy of FORD MOTOR CO.