Manual Transaxle: Assembly: Transaxle

Special Tool(s) 

Fig 1: Transaxle Special Tool (1 Of 2)

Courtesy of FORD MOTOR CO.

Fig 2: Transaxle Special Tool (2 Of 2)

Courtesy of FORD MOTOR CO.

1. Using the special tool, install the input shaft seal.
   Fig 3: Installing Input Shaft Seal Using SST

   Courtesy of FORD MOTOR CO.
2. Install the input shaft bearing cup into the flywheel housing.
   Fig 4: Locating Input Shaft Bearing Cup

   Courtesy of FORD MOTOR CO.
3. Install the input shaft.
   Fig 5: Installing Input Shaft

   Courtesy of FORD MOTOR CO.
4. Position the bearing cup onto the bearing.
   Fig 6: Positioning Bearing Cup Onto Bearing

   Courtesy of FORD MOTOR CO.
5. Position the special tools.
   Fig 7: Positioning Special Tools

   Courtesy of FORD MOTOR CO.
6. Install the transaxle case.
   1. Position the transaxle case.
   2. Install the bolts.
      Fig 8: Locating Transaxle Case

      Courtesy of FORD MOTOR CO.
7. Mount a dial indicator to the transaxle case.
   Fig 9: Mounting Dial Indicator To Transaxle Case

   Courtesy of FORD MOTOR CO.
8. Rotate the input shaft to seat the bearings.
9. Zero the dial indicator.
   Fig 10: Zero 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.
Fig 11: Rotating Input Shaft
Courtesy of FORD MOTOR CO.
10. Rotate the input shaft until the dial indicator returns to zero then raise the input shaft and read the end play.
11. 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 12: Input Shaft Shim Formula

    Courtesy of FORD MOTOR CO.
CAUTION: Do not use more than two shims.
12. 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.
13. Remove the transaxle case, special tools, bearing cup, and input shaft.
14. Install the shim.
    Fig 13: Installing Shim

    Courtesy of FORD MOTOR CO.
15. Using the special tools, install the input shaft bearing cup.
    Fig 14: Installing Input Shaft Bearing Cup Using Special Tools

    Courtesy of FORD MOTOR CO.
16. Install the funnel.
    Fig 15: Installing Funnel

    Courtesy of FORD MOTOR CO.
17. Using the special tools, install the output shaft bearing cup.
    Fig 16: Installing Output Shaft Bearing Cup Using Special Tools

    Courtesy of FORD MOTOR CO.
18. Install the output shaft.
    Fig 17: Installing Output Shaft

    Courtesy of FORD MOTOR CO.
19. Position the bearing cup onto the bearing.
    Fig 18: Positioning Bearing Cup Onto Bearing

    Courtesy of FORD MOTOR CO.
NOTE: The gauge halves must be turned to eliminate any gap between them.
Fig 19: Positioning Special Tools
Courtesy of FORD MOTOR CO.
20. Position the special tools.
21. Install the transaxle case.
    1. Position the transaxle case.
    2. Install the bolts.
       Fig 20: Installing Bolts On Transaxle

       Courtesy of FORD MOTOR CO.
22. Install a dial indicator on the transaxle case.
    Fig 21: Installing Dial Indicator On Transaxle Case

    Courtesy of FORD MOTOR CO.
23. Rotate the output shaft to seat the bearings.
24. Zero the dial indicator.
    Fig 22: 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.
Fig 23: Rotating Output Shaft Until Dial Indicator Returns To Zero
Courtesy of FORD MOTOR CO.
25. Rotate the output shaft until the dial indicator returns to zero then raise the output shaft and read the end play.
26. 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 24: Output Shaft Shim Formula

    Courtesy of FORD MOTOR CO.
CAUTION: Do not use more than two shims.
27. 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.
28. Remove the transaxle case, special tools, bearing cup and output shaft.
29. Install the shim.
    Fig 25: Installing Shim

    Courtesy of FORD MOTOR CO.
30. Using the special tools, install the output shaft bearing cup.
    Fig 26: Installing Output Shaft Bearing Cup Using Special Tool

    Courtesy of FORD MOTOR CO.
31. Using the special tools, install the differential bearing cup into the flywheel housing.
    Fig 27: Install Differential Bearing Cup Into Flywheel Housing Using SST

    Courtesy of FORD MOTOR CO.
32. Install the differential.
    Fig 28: Installing Differential

    Courtesy of FORD MOTOR CO.
33. Position the bearing cup onto the bearing.
    Fig 29: Positioning Bearing Cup Onto Bearing

    Courtesy of FORD MOTOR CO.
NOTE: The gauge halves must be turned to eliminate any gap between them.
Fig 30: Positioning Special Tools
Courtesy of FORD MOTOR CO.
34. Position the special tools.
35. Install the transaxle case.
    1. Position the transaxle case.
    2. Install the bolts.
       Fig 31: Installing Transaxle Case

       Courtesy of FORD MOTOR CO.
36. Using the special tool, adjust gauge until the free play is removed. Turn gauge back together.
    Fig 32: Adjust Gauge Using Special Tool

    Courtesy of FORD MOTOR CO.
37. Insert the special tool through the transaxle case and engage the differential pinion shaft.
    Fig 33: Inserting Special Tool Through Transaxle Case

    Courtesy of FORD MOTOR CO.
38. Using the special tools, adjust gauge until the differential rotation is within specification.
    Fig 34: Adjusting Gauge Using Special Tools

    Courtesy of FORD MOTOR CO.
39. Measure the gap in the special tool.
    Fig 35: Measuring Gap In Special Tool

    Courtesy of FORD MOTOR CO.
40. Add 0.15 mm (0.0059 in) to the measurement to achieve the final clearance.
CAUTION: Do not use more than two differential shims.
Fig 36: Shim Thickness Table (1 Of 2)
Courtesy of FORD MOTOR CO.
Fig 37: Shim Thickness Table (2 Of 2)
Courtesy of FORD MOTOR CO.
41. Use the following chart 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, special tools, bearing cup, and differential.
43. Install the differential bearing cup shim(s) into the transaxle case.
    Fig 38: Installing Differential Bearing Cup

    Courtesy of FORD MOTOR CO.
44. Using the special tools, install the differential bearing cup into the transaxle case.
    Fig 39: Installing Differential Bearing Cup Into Transaxle Case Using Special Tool

    Courtesy of FORD MOTOR CO.
NOTE: Transaxle case side shown, flywheel housing side similar.
Fig 40: Installing Halfshaft Seals Using Special Tool
Courtesy of FORD MOTOR CO.
45. Using the special tool, install the halfshaft seals.
46. Install the reverse lever and shaft.
    1. Position the reverse lever.
    2. Install the reverse lever shaft.
       Fig 41: Installing Reverse Lever Shaft

       Courtesy of FORD MOTOR CO.
47. Install the reverse lever roll pin.
    Fig 42: Installing Reverse Lever Roll Pin

    Courtesy of FORD MOTOR CO.
48. Install the vent tube and the vent tube bolts.
    Fig 43: Installing Vent Tube And Vent Tube Bolts

    Courtesy of FORD MOTOR CO.
49. Using the special tool, install the shift control shaft seal.
    Fig 44: Installing Shift Control Shaft Seal Using Special Tool

    Courtesy of FORD MOTOR CO.
NOTE: Install the boot with the drain hole facing downward when installed in the vehicle.
Fig 45: Installing Shift Control Shaft Assembly
Courtesy of FORD MOTOR CO.
50. Install the shift control shaft assembly.
51. Install a new roll pin.
    Fig 46: Installing New Roll Pin

    Courtesy of FORD MOTOR CO.
52. Install the shift control shaft selector lever.
    1. Position the shift control shaft selector lever.
    2. Install the shift control shaft selector lever bolt.
       Fig 47: Installing Shift Control Shaft Selector Lever

       Courtesy of FORD MOTOR CO.
53. Install the shift control selector plate and spacer.
    1. Position the shift control selector plate and spacer.
    2. Install the bolts.
       Fig 48: Locating Bolts

       Courtesy of FORD MOTOR CO.
54. Install the differential.
    Fig 49: Installing Differential

    Courtesy of FORD MOTOR CO.
55. Install the output and input shafts as an assembly.
    Fig 50: Installing Output And Input Shafts As An Assembly

    Courtesy of FORD MOTOR CO.
56. Install the gear shifter fork and main shift control shaft assembly, spring and detent ball.
    Fig 51: Installing Gear Shifter Fork

    Courtesy of FORD MOTOR CO.
57. Shift into second and fourth gears.
58. Install the shift lever shaft and shift fork selector lever.
    1. Install the shift fork selector lever.
    2. Install the shift lever shaft.
       Fig 52: Installing Shift Lever Shaft

       Courtesy of FORD MOTOR CO.
59. Install the shift lever shaft roll pin.
    Fig 53: Installing Shift Lever Shaft Roll Pin

    Courtesy of FORD MOTOR CO.
60. Install the shift control shaft and shift gate.
    1. Install the shift gate.
    2. Install the shift control shaft.
       Fig 54: Installing Shift Control Shaft And Shift Gate

       Courtesy of FORD MOTOR CO.
61. Install the shift gate bolt.
    Fig 55: Installing Shift Gate Bolt

    Courtesy of FORD MOTOR CO.
62. Install the reverse idler gear.
    1. Install reverse idler gear.
    2. Install reverse idler gear shaft.
       Fig 56: Installing Reverse Idler Gear Shaft

       Courtesy of FORD MOTOR CO.
63. Install the magnet.
    Fig 57: Installing Magnet

    Courtesy of FORD MOTOR CO.
64. Position the gear selector arm and reverse idler gear shaft.
    1. Align the end of the gear selector interlock sleeve with the gear selector arm.
    2. Face the reverse idler gear shaft hole in the direction shown.
       Fig 58: Positioning Gear Selector Arm And Reverse Idler Gear Shaft

       Courtesy of FORD MOTOR CO.
CAUTION: The transaxle case must be installed within four minutes after applying silicone gasket and sealant.
65. Apply a small bead of silicone gasket and sealant to the transaxle mating surface.
66. Install the transaxle case.
    1. Position the transaxle case.
    2. Install the 15 bolts.
       Fig 59: Installing Transaxle Case

       Courtesy of FORD MOTOR CO.
67. Install the lock bolt, spring, and ball.
    Fig 60: Installing Lock Bolt, Spring, And Ball

    Courtesy of FORD MOTOR CO.
CAUTION: Make sure that the shift rail guide bolt is in the groove of the shift rail.
Fig 61: Installing Reverse Idler Shaft Lock Bolt
Courtesy of FORD MOTOR CO.
68. Install the reverse idler shaft lock bolt and shift rail guide bolt.
69. Install the fifth speed gear.
    Fig 62: Installing Fifth Speed Gear

    Courtesy of FORD MOTOR CO.
70. Install the fifth gear bushing.
    Fig 63: Installing Fifth Gear Bushing

    Courtesy of FORD MOTOR CO.
71. Measure the clearance between the reverse/fifth synchronizer sleeve and its shift fork.
    Fig 64: Measuring Clearance Between Reverse/Fifth Synchronizer Sleeve And Its Shift Fork

    Courtesy of FORD MOTOR CO.
72. Install the fifth speed cluster gear.
    Fig 65: Installing Fifth Speed Cluster Gear

    Courtesy of FORD MOTOR CO.
CAUTION: The synchronizer blocking rings are not interchangeable. Make sure to keep them in the order that they were removed.
Fig 66: Installing Synchronizer Blocking Ring
Courtesy of FORD MOTOR CO.
73. Install the synchronizer blocking ring.
74. Install the reverse/fifth shift fork and synchronizer hub assembly.
    Fig 67: Installing Synchronizer Blocking Ring

    Courtesy of FORD MOTOR CO.
75. Install a new reverse/fifth shift fork roll pin.
    Fig 68: Installing New Reverse/Fifth Shift Fork Roll Pin

    Courtesy of FORD MOTOR CO.
CAUTION: The synchronizer blocking rings are not interchangeable. Make sure to install them in the order that they were removed.
Fig 69: Installing Reverse Synchronizer Blocking Ring
Courtesy of FORD MOTOR CO.
76. Install the reverse synchronizer blocking ring.
77. Shift the transaxle into first gear.
CAUTION: Do not reuse locknuts.
CAUTION: Stake the locknuts.
78. Install the input and output shaft locknuts.
    1. Using the special tool, keep the input shaft from turning.
    2. Install new input and output shaft locknuts.
       Fig 70: Installing New Input And Output Shaft Locknuts

       Courtesy of FORD MOTOR CO.
CAUTION: The case cover must be installed within four minutes after applying silicone gasket and sealant.
79. Apply a small bead of silicone gasket and sealant to the case and cover mating surface.
80. Install the case cover.
    1. Position the case cover.
    2. Install the bolts.
       Fig 71: Installing Case Cover

       Courtesy of FORD MOTOR CO.
81. Install the clutch slave cylinder line bracket.
    1. Position the clutch slave cylinder line bracket.
    2. Install the bolts.
       Fig 72: Installing Clutch Slave Cylinder Line Bracket

       Courtesy of FORD MOTOR CO.
82. Install the reversing lamp switch.
    Fig 73: Installing Reversing Lamp Switch

    Courtesy of FORD MOTOR CO.
83. Rotate the transaxle 180 degrees.
84. Install the park/neutral position (PNP) switch.
    Fig 74: Installing The Park/Neutral Position (PNP) Switch

    Courtesy of FORD MOTOR CO.
85. Install the anchor bolt.
    Fig 75: Installing Anchor Bolt

    Courtesy of FORD MOTOR CO.
86. Install the clutch release fork and bearing.
    1. Install the clutch release fork and bearing.
    2. Install the boot.
       Fig 76: Installing Clutch Release Fork And Bearing

       Courtesy of FORD MOTOR CO.
87. Remove the transaxle from the special tool.
    Fig 77: Removing Transaxle From Special Tool

    Courtesy of FORD MOTOR CO.