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Manual Transmission: Assembly: Transaxle

Fig 1: Identifying Special Tools (1 Of 4)
G02207678Courtesy of FORD MOTOR CO.
Fig 2: Identifying Special Tools (2 Of 4)
G02207679Courtesy of FORD MOTOR CO.
Fig 3: Identifying Special Tools (3 Of 4)
G02207680Courtesy of FORD MOTOR CO.
Fig 4: Identifying Special Tools (4 Of 4)
G02207681Courtesy of FORD MOTOR CO.
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 on the case side.
  1. Install the input shaft bearing cup into the flywheel housing.
    Fig 5: Installing Input Shaft Bearing Cup Into Flywheel Housing
    G02207682Courtesy of FORD MOTOR CO.
  2. Install the input shaft.
    Fig 6: Installing Input Shaft
    G02207683Courtesy of FORD MOTOR CO.
  3. Position the bearing cup onto the bearing, then install Shim Selection Gauge on the bearing cup.
    Fig 7: Installing Shim Selection Gauge On Bearing Cup
    G02207684Courtesy of FORD MOTOR CO.
  4. Position collars onto the flywheel housing.
    Fig 8: Positioning Collars Onto Flywheel Housing
    G02207685Courtesy of FORD MOTOR CO.
  5. Position the transaxle case on collars and install the bolts.
    Fig 9: Installing Bolts
    G02207686Courtesy of FORD MOTOR CO.
  6. Mount Dial Indicator and Dial Indicator Bracketry on the transaxle case.
    Fig 10: Mounting Dial Indicator And Dial Indicator Bracketry On Transaxle Case
    G02207687Courtesy of FORD MOTOR CO.
  7. Rotate the input shaft to seat the bearings.
  8. Zero Dial Indicator.
    Fig 11: Identifying Dial Indicator
    G02207688Courtesy of FORD MOTOR CO.
    9. CAUTION: The shaft must be lifted equally on both sides or it may cock to one side, resulting in an incorrect reading.
    Fig 12: Identifying Dial Indicator Position
    G02207689Courtesy of FORD MOTOR CO.
  9. Rotate the input shaft until Dial Indicator returns to zero. Raise the input shaft and read the end play.
  10. Repeat the previous step to obtain three readings within 0.10 mm (0.004 in) of each other. Use the formula in Fig 13 to select the correct shim size.
    Fig 13: Correct Shim Size Chart
    G02207690Courtesy of FORD MOTOR CO.
    11. NOTE: Do not use more than two shims.
  11. From Shim Selection Kit meeting Ford specification, select the shim(s) that is closest to (or slightly thinner than) the final shim size determined in the previous step.
  12. Remove the transaxle case, gauge, bearing cup, and input shaft.
  13. Install the shim.
    Fig 14: Installing Shim
    G02207691Courtesy of FORD MOTOR CO.
  14. Use (A) Driver Handle and (B) Bearing Cup Replacer to install the (C) input shaft bearing cup.
    Fig 15: Installing Input Shaft Bearing Cup
    G02207692Courtesy of FORD MOTOR CO.
  15. Install the fifth shaft funnel and the output shaft bearing cup.
    1. Install the fifth shaft funnel.
      Fig 16: Installing Fifth Shaft Funnel And Output Shaft Bearing Cup
      G02207693Courtesy of FORD MOTOR CO.
    2. Install the output shaft bearing cup.
  16. Install the output shaft.
    Fig 17: Installing Output Shaft
    G02207694Courtesy of FORD MOTOR CO.
  17. Position the bearing cup onto the bearing.
    Fig 18: Positioning Bearing Cup Onto Bearing
    G02207695Courtesy of FORD MOTOR CO.
    18. NOTE: The gauge halves must be turned to eliminate any gap between them.
    Fig 19: Positioning Shim Selection Gauge On Bearing Cup
    G02207696Courtesy of FORD MOTOR CO.
  18. Position Shim Selection Gauge on the bearing cup.
  19. Position collars onto the flywheel housing.
    Fig 20: Positioning Collars Onto Flywheel Housing
    G02207697Courtesy of FORD MOTOR CO.
  20. Position the transaxle case on collars and install the bolts.
    Fig 21: Installing Bolts
    G02207698Courtesy of FORD MOTOR CO.
  21. Mount Dial Indicator and Dial Indicator Bracketry on the transaxle case.
    Fig 22: Mounting Dial Indicator And Dial Indicator Bracketry On Transaxle Case
    G02207699Courtesy of FORD MOTOR CO.
  22. Rotate the output shaft to seat the bearings.
  23. Zero Dial Indicator.
    Fig 23: Identifying Dial Indicator Position
    G02207700Courtesy of FORD MOTOR CO.
    24. CAUTION: The shaft must be lifted equally on both sides or it may cock to one side, resulting in an incorrect reading.
    Fig 24: Placing Dial Indicator On Output Shaft
    G02207701Courtesy of FORD MOTOR CO.
  24. Rotate the output shaft until Dial Indicator returns to zero. Raise the output shaft and read the end play.
  25. Repeat the previous step to obtain three readings within 0.10 mm (0.004 in) of each other. Use the formula below to select the correct shim size.
    Fig 25: Installing Shim
    G02207702Courtesy of FORD MOTOR CO.
    26. NOTE: Do not use more than two shims.
  26. From Shim Selection Kit meeting Ford specification, select the shim(s) that is closest to (or slightly thinner than) the final shim size determined in the previous step.
  27. Remove the transaxle case, gauge, bearing cup and output shaft.
  28. Install the shim.
    Fig 26: Installing Shim
    G02207703Courtesy of FORD MOTOR CO.
  29. Use (A) Driver Handle and (B) Bearing Cup Replacer to install the (C) output shaft bearing cup.
    Fig 27: Correct Shim Size Chart
    G02207704Courtesy of FORD MOTOR CO.
  30. Use (A) Differential Bearing Cone Replacer and (B) Driver Handle to install the (C) differential bearing cup into the flywheel housing.
    Fig 28: Installing Differential Bearing Cup Into Flywheel Housing
    G02207705Courtesy of FORD MOTOR CO.
  31. Install the differential.
    Fig 29: Installing Differential
    G02207706Courtesy of FORD MOTOR CO.
  32. Position the bearing cup onto the bearing.
    Fig 30: Positioning Bearing Cup Onto Bearing
    G02207707Courtesy of FORD MOTOR CO.
    33. NOTE: The gauge halves must be turned to eliminate any gap between them.
    Fig 31: Placing Shim Selection Gauge Onto Bearing Cup
    G02207708Courtesy of FORD MOTOR CO.
  33. Place Shim Selection Gauge onto the bearing cup.
  34. Position collars on the flywheel housing.
    Fig 32: Positioning Collars On Flywheel Housing
    G02207709Courtesy of FORD MOTOR CO.
  35. Position the transaxle case on collars and install the bolts.
    Fig 33: Installing Bolts
    G02207710Courtesy of FORD MOTOR CO.
  36. Use (A) pins to adjust (B) Shim Selection Gauge until the free play is removed. Turn Shim Selection Gauge back together.
    Fig 34: Using Pins To Adjust Shim Selection Gauge
    G02207711Courtesy of FORD MOTOR CO.
  37. Insert Differential Rotator through the transaxle case and engage the differential pinion shaft.
    Fig 35: Inserting Differential Rotator Through Transaxle Case
    G02207712Courtesy of FORD MOTOR CO.
  38. Use pins to adjust Shim Selection Gauge until the differential rotation is within specification.
    Fig 36: Using Pins To Adjust Shim Selection Gauge
    G02207713Courtesy of FORD MOTOR CO.
  39. Use a feeler gauge to measure the gap in Shim Selection Gauge.
    Fig 37: Measuring Gap In Shim Selection Gauge Using Feeler Gauge
    G02207714Courtesy of FORD MOTOR CO.
  40. Add 0.15 mm (0.0059 in) to the feeler gauge measurement to achieve the final clearance.
    41. NOTE: Do not use more than two differential shims.
    Fig 38: Shims Specifications (1 Of 2)
    G02207715Courtesy of FORD MOTOR CO.
    Fig 39: Shims Specifications (2 Of 2)
    G02207716Courtesy of FORD MOTOR CO.
  41. Use Fig 38 and Fig 39 to select the differential bearing shims that are closest to (or slightly larger than) the value obtained in Step 40.
  42. Remove the transaxle case, gauge, bearing cup, and differential.
  43. Install the differential shim(s) into the transaxle case.
    Fig 40: Installing Differential Shim Into Transaxle Case
    G02207717Courtesy of FORD MOTOR CO.
  44. Use (A) Differential Bearing Cone Replacer and (B) Driver Handle to install the differential bearing cup into the (C) transaxle case.
    Fig 41: Installing Differential Bearing Cup Into Transaxle Case
    G02207718Courtesy of FORD MOTOR CO.
  45. Use Differential Seal Replacer to install the differential seals.
    Fig 42: Installing Differential Seals Using Differential Seal Replacer
    G02207719Courtesy of FORD MOTOR CO.
  46. Use Bell Housing Seal Replacer to install the input shaft oil seal.
    Fig 43: Installing Input Shaft Oil Seal Using Bell Housing Seal Replacer
    G02207720Courtesy of FORD MOTOR CO.
  47. Install the park/neutral position (PNP) switch and gasket.
    Fig 44: Installing Park/Neutral Position (PNP) Switch And Gasket
    G02207721Courtesy of FORD MOTOR CO.
  48. Install the reverse lever and shaft.
    1. Install the reverse lever.
      Fig 45: Installing Reverse Lever And Shaft
      G02207722Courtesy of FORD MOTOR CO.
    2. Install the reverse lever shaft.
  49. Install the reverse lever roll pin.
    Fig 46: Installing Reverse Lever Roll Pin
    G02207723Courtesy of FORD MOTOR CO.
  50. Install the vent tube and the vent tube bolts.
    Fig 47: Installing Vent Tube And Vent Tube Bolts
    G02207724Courtesy of FORD MOTOR CO.
  51. Use (A) Shift Lever Seal Replacer to install the (B) shift shaft seal.
    Fig 48: Installing Shift Shaft Seal
    G02207725Courtesy of FORD MOTOR CO.
    52. NOTE: Install the boot with the drain hole facing downward when installed in the vehicle.
    Fig 49: Installing Shift Control Shaft Assembly
    G02207726Courtesy of FORD MOTOR CO.
  52. Install the shift control shaft assembly.
  53. Install the shift control selector roll pin.
    Fig 50: Installing Shift Control Selector Roll Pin
    G02207727Courtesy of FORD MOTOR CO.
  54. Install the shift control shaft selector lever and bolt.
    1. Position the shift control shaft selector lever.
      Fig 51: Installing Shift Control Shaft Selector Lever & Bolt
      G02207728Courtesy of FORD MOTOR CO.
    2. Install the shift control shaft selector lever bolt.
  55. Install the selector plate and spacer and bolts.
    1. Position the control selector plate and spacer.
    2. Install the bolts.
      Fig 52: Installing Bolts
      G02207729Courtesy of FORD MOTOR CO.
  56. Install the differential.
    Fig 53: Installing Differential
    G02207730Courtesy of FORD MOTOR CO.
  57. Install the output and input shafts as an assembly.
    Fig 54: Installing Output And Input Shafts
    G02207731Courtesy of FORD MOTOR CO.
  58. Install the shift fork shaft assembly, spring and detent ball.
    Fig 55: Installing Shift Fork Shaft Assembly, Spring And Detent Ball
    G02207732Courtesy of FORD MOTOR CO.
  59. Shift into second and fourth gears.
  60. Install the shift control shaft and shift fork selector lever.
    1. Install the shift fork selector lever.
      Fig 56: Installing Shift Fork Selector Lever & Control Shaft
      G02207733Courtesy of FORD MOTOR CO.
    2. Install shift control shaft.
  61. Install the roll pin.
    Fig 57: Installing Roll Pin
    G02207734Courtesy of FORD MOTOR CO.
  62. Install the shift control rod.
    1. Install the shift gate.
      Fig 58: Installing Shift Gate & Control Rod
      G02207735Courtesy of FORD MOTOR CO.
    2. Install the shift control rod.
  63. Install the shift gate bolt.
    Fig 59: Installing Shift Gate Bolt
    G02207736Courtesy of FORD MOTOR CO.
  64. Install the reverse idler shaft and gear.
    1. Install reverse gear.
      Fig 60: Installing Reverse Gear & Idler Shaft
      G02207737Courtesy of FORD MOTOR CO.
    2. Install reverse idler shaft.
  65. Install the magnet.
    Fig 61: Installing Magnet
    G02207738Courtesy of FORD MOTOR CO.
  66. Position the gear selector arm and reverse idler shaft.
    1. Align the end of the gear selector interlock sleeve with the gear selector arm.
      Fig 62: Positioning Gear Selector Arm And Reverse Idler Shaft
      G02207739Courtesy of FORD MOTOR CO.
    2. Face the reverse idler shaft hole in the direction shown in Fig 62.
    67. NOTE: The transaxle case must be installed within four minutes after applying Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6.
  67. Apply a small bead of Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6 to the transaxle mating surface.
  68. Install the transaxle case and bolts.
    1. Install the transaxle case.
      Fig 63: Installing Transaxle Case And Bolts
      G02207740Courtesy of FORD MOTOR CO.
    2. Install the thirteen bolts.
  69. Position the transaxle mount bracket and install the bolts.
    Fig 64: Installing Bolts
    G02207741Courtesy of FORD MOTOR CO.
  70. Install the backup lamp switch.
    Fig 65: Installing Backup Lamp Switch
    G02207742Courtesy of FORD MOTOR CO.
  71. Install the lock bolt, spring, and ball.
    Fig 66: Installing Lock Bolt, Spring, And Ball
    G02207743Courtesy of FORD MOTOR CO.
    72. NOTE: Ensure that the bolt is in the groove of the shift rail.
    Fig 67: Installing Shift Rail Guide Bolt
    G02207744Courtesy of FORD MOTOR CO.
  72. Install the shift rail guide bolt.
  73. Install the reverse idler shaft lock bolt.
    Fig 68: Installing Reverse Idler Shaft Lock Bolt
    G02207745Courtesy of FORD MOTOR CO.
  74. Install the fifth gear and the output shaft fifth gear spacer.
    1. Install fifth gear.
      Fig 69: Installing Output Shaft Fifth Gear & Spacer
      G02207746Courtesy of FORD MOTOR CO.
    2. Install the output shaft fifth gear spacer.
  75. Install the fifth gear bushing.
    Fig 70: Installing Fifth Gear Bushing
    G02207747Courtesy of FORD MOTOR CO.
  76. Measure the clearance between the fifth/reverse synchronizer sleeve and its shift fork.
    Fig 71: Measuring Clearance Between Fifth/Reverse Synchronizer Sleeve And Shift Fork
    G02207748Courtesy of FORD MOTOR CO.
  77. Install the input shaft fifth gear.
    Fig 72: Installing Input Shaft Fifth Gear
    G02207749Courtesy of FORD MOTOR CO.
    78. CAUTION: The synchronizer blocking rings are not interchangeable. Be sure to keep them in the order that they were removed.
    Fig 73: Installing Synchronizer Blocking Ring
    G02207750Courtesy of FORD MOTOR CO.
  78. Install the synchronizer blocking ring.
  79. Install the fifth/reverse shift fork and synchronizer hub assembly.
    Fig 74: Installing Fifth/Reverse Shift Fork And Synchronizer Hub Assembly
    G02207751Courtesy of FORD MOTOR CO.
  80. Install the shift fork roll pin.
    Fig 75: Installing Shift Fork Roll Pin
    G02207752Courtesy of FORD MOTOR CO.
    81. CAUTION: The synchronizer blocking rings are not interchangeable. Be sure to keep them in the order that they were removed.
    Fig 76: Installing Synchronizer Blocking Ring
    G02207753Courtesy of FORD MOTOR CO.
  81. Install the synchronizer blocking ring.
  82. Install the reverse synchronizer blocking ring retainer assembly.
    1. Install the retainer.
      Fig 77: Installing Reverse Synchronizer Blocking Ring Retainer & Spacer
      G02207754Courtesy of FORD MOTOR CO.
    2. Install the spacer.
  83. Shift the transaxle into first gear.
    84. CAUTION: Do not reuse locknuts.
    CAUTION: Stake the locknuts.
    Fig 78: Installing Input And Output Locknuts
    G02207755Courtesy of FORD MOTOR CO.
  84. Use Input Shaft Holder to install the input and output locknuts.
    85. NOTE: The case cover must be installed within four minutes after applying Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6.
  85. Apply a small bead of Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6 to the case and cover mating surface.
  86. Install the case cover and bolts.
    1. Install the case cover.
      Fig 79: Installing Case Cover And Bolts
      G02207756Courtesy of FORD MOTOR CO.
    2. Install the bolts.
  87. Remove the transaxle from Bench Mounted Holding Fixture.
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