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Manual Transmission: Disassembly: Transaxle

Fig 1: Identifying Special Tools (1 Of 2)

G02207576

Courtesy of FORD MOTOR CO.

Fig 2: Identifying Special Tools (2 Of 2)

G02207577

Courtesy of FORD MOTOR CO.

Fig 3: Exploded View Of Transaxle Assembly Components

G02207578

Courtesy of FORD MOTOR CO.

Clean the transaxle exterior with solvent before disassembly.
Clean all removed parts (except sealed bearings) and all sealing surfaces with solvent, and dry with compressed air.

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.

Clean out all holes and passages with compressed air and verify that there are no obstructions.
Mount the transaxle on Bench Mounted Holding Fixture.

Fig 4: Mounting Transaxle On Bench Mounted Holding Fixture
Courtesy of FORD MOTOR CO.
Remove the case cover.
1. Remove the bolts.
  
  Fig 5: Removing Case Cover
  Courtesy of FORD MOTOR CO.
2. Remove the case cover.
Shift the transaxle into first gear.

CAUTION: Do not reuse locknuts.

Fig 6: Removing Input And Output Locknuts

G02207581

Courtesy of FORD MOTOR CO.

Use Input Shaft Holder to remove the input and output locknuts. Discard the input and output locknuts.
Remove the reverse synchronizer blocking ring retainer assembly.
1. Remove the spacer.
  
  Fig 7: Removing Reverse Synchronizer Blocking Ring Retainer Assembly
  Courtesy of FORD MOTOR CO.
2. Remove the reverse synchronizer blocking ring retainer assembly.
Remove the reverse synchronizer blocking ring.

Fig 8: Removing Reverse Synchronizer Blocking Ring
Courtesy of FORD MOTOR CO.
Remove and discard the reverse/fifth shift fork roll pin.

Fig 9: Removing Reverse/Fifth Shift Fork Roll Pin
Courtesy of FORD MOTOR CO.
Remove the reverse/fifth shift fork and synchronizer hub assembly.

Fig 10: Removing Reverse/Fifth Shift Fork And Synchronizer Hub Assembly
Courtesy of FORD MOTOR CO.
Remove the synchronizer blocking ring.

Fig 11: Removing Synchronizer Blocking Ring
Courtesy of FORD MOTOR CO.
Remove the input shaft fifth gear.

Fig 12: Removing Input Shaft Fifth Gear
Courtesy of FORD MOTOR CO.
Remove the fifth gear bushing.

Fig 13: Removing Fifth Gear Bushing
Courtesy of FORD MOTOR CO.
Remove the output shaft fifth gear spacer and fifth gear.
1. Remove the fifth gear spacer.
  
  Fig 14: Removing Fifth Output Shaft Gear & Spacer
  Courtesy of FORD MOTOR CO.
2. Remove the fifth output shaft gear.
Remove the reverse idler shaft lock bolt.

Fig 15: Removing Reverse Idler Shaft Lock Bolt
Courtesy of FORD MOTOR CO.
Remove the shift rail guide bolt.

Fig 16: Removing Shift Rail Guide Bolt
Courtesy of FORD MOTOR CO.
Remove the lock bolt, spring, and ball.

Fig 17: Removing Lock Bolt, Spring, And Ball
Courtesy of FORD MOTOR CO.
Remove the backup lamp switch.

Fig 18: Removing Backup Lamp Switch
Courtesy of FORD MOTOR CO.
Remove the transaxle mount bracket.
1. Remove the bolts.
  
  Fig 19: Removing Transaxle Mount Bracket
  Courtesy of FORD MOTOR CO.
2. Remove the transaxle mount bracket.
Separate the transaxle case.
1. Remove the thirteen transaxle case bolts.
  
  Fig 20: Removing Transaxle Case & Bolts
  Courtesy of FORD MOTOR CO.
2. Separate the transaxle case.
Remove the magnet.

Fig 21: Removing Magnet
Courtesy of FORD MOTOR CO.
Remove the reverse idler gear.
1. Remove the reverse idler shaft.
  
  Fig 22: Removing Reverse Idler Gear & Shaft
  Courtesy of FORD MOTOR CO.
2. Remove the reverse idler gear.
Remove the shift gate bolt.

Fig 23: Removing Shift Gate Bolt
Courtesy of FORD MOTOR CO.
Remove the shift control rod and gate.
1. Remove the shift control rod.
  
  Fig 24: Removing Shift Control Rod & Gate
  Courtesy of FORD MOTOR CO.
2. Remove the shift gate.
Remove the shift control shaft roll pin.

Fig 25: Removing Shift Control Shaft Roll Pin
Courtesy of FORD MOTOR CO.
Remove the shift control shaft and shift fork selector lever.
1. Remove the shift control rod.
  
  Fig 26: Removing Shift Control Rod & Fork Selector Lever
  Courtesy of FORD MOTOR CO.
2. Remove the shift fork selector lever.
Shift into second and fourth gears.

WARNING: When removing the shift fork and shaft assembly the detent ball will fly out. Hold a shop towel over the detent ball and spring to prevent the ball from becoming airborne.

Fig 27: Removing Shift Fork Shaft Assembly

G02207602

Courtesy of FORD MOTOR CO.

Remove the shift fork shaft assembly, detent ball and spring.
Remove the output and input shafts as an assembly.

Fig 28: Removing Output And Input Shafts
Courtesy of FORD MOTOR CO.
Remove the differential.

Fig 29: Removing Differential
Courtesy of FORD MOTOR CO.
Remove the input bearing cups.

Fig 30: Removing Input Bearing Cups
Courtesy of FORD MOTOR CO.
Remove the input shaft oil seal.
1. Attach Puller to the input shaft oil seal.
  
  Fig 31: Attaching Puller & Removing Input Shaft Oil Seal
  Courtesy of FORD MOTOR CO.
2. Remove the input shaft oil seal.
Remove the fifth shaft funnel.
1. Remove the output shaft bearing cup.
  
  Fig 32: Removing Bearing Cup & Fifth Shaft Funnel
  Courtesy of FORD MOTOR CO.
2. Remove the fifth shaft funnel.
Remove the control selector plate and spacer.
1. Remove the bolts.
  
  Fig 33: Removing Bolts & Control Selector Plate And Spacer
  Courtesy of FORD MOTOR CO.
2. Remove the control selector plate and spacer.
Remove the shift control shaft selector lever.
1. Remove the bolt.
  
  Fig 34: Removing Bolt & Shift Control Shaft Selector Lever
  Courtesy of FORD MOTOR CO.
2. Remove the shift control shaft selector lever.
Remove and discard the roll pin.

Fig 35: Removing And Discard Roll Pin
Courtesy of FORD MOTOR CO.
Remove the shift control shaft assembly.

Fig 36: Removing Shift Control Shaft Assembly
Courtesy of FORD MOTOR CO.
Use (A) collet, (B) actuator pin and (C) hammer from Blind Hole Puller Set to remove the (D) shifter shaft seal.

Fig 37: Removing Shifter Shaft Seal
Courtesy of FORD MOTOR CO.
Remove the vent tube.
1. Remove the bolts.
  
  Fig 38: Removing Bolts & Vent Tube
  Courtesy of FORD MOTOR CO.
2. Remove the vent tube.
Remove the retaining bolt and the vehicle speed sensor (VSS).

Fig 39: Removing Retaining Bolt And Vehicle Speed Sensor
Courtesy of FORD MOTOR CO.
Use (A) Stator and Driven Sprocket Bearing Remover, (B) Disc Brake Piston Remover, and (C) Impact Slide Hammer to remove the (D) differential bearing cups.

Fig 40: Removing Differential Bearing Cups
Courtesy of FORD MOTOR CO.
Remove and discard the reverse lever roll pin.

Fig 41: Removing Reverse Lever Roll Pin
Courtesy of FORD MOTOR CO.
Remove the reverse lever shaft.
1. Remove the reverse lever shaft.
  
  Fig 42: Removing Reverse Lever & Shaft
  Courtesy of FORD MOTOR CO.
2. Remove the reverse lever.
Remove the park/neutral position (PNP) switch and gasket.

Fig 43: Removing Park/Neutral Position (PNP) Switch And Gasket
Courtesy of FORD MOTOR CO.
Use (A) Bearing Cup Puller and (B) Impact Slide Hammer to remove the (C) differential seals.

Fig 44: Removing Differential Seals
Courtesy of FORD MOTOR CO.
Use (A) Puller to remove the (B) input and output shaft bearing ups.

Fig 45: Removing Input And Output Shaft Bearing Ups
Courtesy of FORD MOTOR CO.