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Transaxle Case - Assembly: Assembly

WARNING: This page is about a different car, the 2006 Mercury Montego, 2006 Ford Freestyle, and 2006 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.
  1. Position the differential bearing race in place.
    Fig 1: Locating Differential Bearing Race
    G04656835Courtesy of FORD MOTOR CO.
  2. Install the special tools.
    Fig 2: Identifying Special Tools (204-029, 307-531)
    G04656836Courtesy of FORD MOTOR CO.
  3. Install the remaining tools from the other side of the case. Using the special tool, install the bearing race.
    Fig 3: Identifying Special Tools (204-029, 307-530-1)
    G04656837Courtesy of FORD MOTOR CO.
    4. CAUTION: When positioning the bearing in the case, make sure that the bearing is correctly aligned with the case. Damage to the case will occur when the bearing is not aligned with the case.
    Fig 4: Locating Secondary Variator Bearing
    G04656838Courtesy of FORD MOTOR CO.
  4. Position the secondary variator bearing in place (sealed bearing).
  5. Install the special tool.
    Fig 5: Identifying Special Tool (307-536)
    G04656839Courtesy of FORD MOTOR CO.
  6. From the other side of the case assemble the remaining tools.
    Fig 6: Identifying Special Tools (204-029, 307-530-1)
    G04656840Courtesy of FORD MOTOR CO.
  7. Using the special tools, install the secondary bearing.
    Fig 7: Identifying Special Tools (204-029, 307-541)
    G04656841Courtesy of FORD MOTOR CO.
    8. CAUTION:
    1. When positioning the bearing in the case, make sure that the bearing is correctly aligned with the case. Damage to the case will occur when the bearing is not aligned with the case.
    2. When positioning the primary variator bearing into the case, make sure that the raised portion of the bearing is facing up, or damage to the transaxle will occur.
    Fig 8: Locating Primary Variator Bearing
    G04656842Courtesy of FORD MOTOR CO.
  8. Position the primary variator bearing in place (roller type bearing).
  9. Install the special tool.
    Fig 9: Identifying Special Tool (307-563)
    G04656843Courtesy of FORD MOTOR CO.
  10. From the other side of the case, assemble the remaining special tools.
    Fig 10: Identifying Special Tools (204-029, 307-530-1)
    G04656844Courtesy of FORD MOTOR CO.
  11. Using the special tools, install the primary bearing.
    Fig 11: Identifying Special Tools (204-029, 307-563)
    G04656845Courtesy of FORD MOTOR CO.
  12. Install the secondary bearing cover plate and the bolts.
    • Tighten the bolts in a crisscross pattern.
    • Tighten to 11 N.m (8 lb-ft).
    Fig 12: Locating Secondary Bearing Cover Plate
    G04656846Courtesy of FORD MOTOR CO.
  13. If the park system components have not been removed then install the primary bearing cover plate at this time.
    • Tighten the bolts in a crisscross pattern.
    • Tighten to 11 N.m (8 lb-ft).
    Fig 13: Locating Primary Bearing Cover Plate
    G04656847Courtesy of FORD MOTOR CO.
  14. If removed, install the primary variator feed tube into the case.
    Fig 14: Locating Primary Variator Feed Tube
    G04656848Courtesy of FORD MOTOR CO.
  15. If the primary variator feed tube was removed, install the primary bearing cover plate and the bolts.
    • Tighten the bolts in a crisscross pattern.
    • Tighten to 11 N.m (8 lb-ft).
    Fig 15: Locating Primary Bearing Cover Plate
    G04656849Courtesy of FORD MOTOR CO.
  16. If removed, install the park pawl.
    Fig 16: Locating Park Pawl
    G04656850Courtesy of FORD MOTOR CO.
    17. NOTE: Note the correct location of the spring.
    Fig 17: Locating Park Pawl Spring & Guide Pin
    G04656851Courtesy of FORD MOTOR CO.
  17. If removed, install the park pawl spring and guide pin.
  18. If removed, install the manual lever and park rod in the case.
    1. Install the manual lever and park rod into the case.
    2. Hold the park pawl back.
    3. Position the park rod into the case.
    Fig 18: Identifying Manual Lever & Park Rod
    G04656852Courtesy of FORD MOTOR CO.
  19. Lubricate the new O-ring seal with clean continuously variable transaxle (CVT) transmission fluid and install the O-ring seal on the primary variator feed tube.
    Fig 19: Locating O-Ring Seal (1 Of 2)
    G04656853Courtesy of FORD MOTOR CO.
  20. Lubricate the new O-ring seals with clean CVT transmission fluid and install the O-ring seals onto the manual valve feed tube.
    Fig 20: Locating O-Ring Seal (2 Of 2)
    G04656854Courtesy of FORD MOTOR CO.
  21. Install the manual valve feed tube in the case.
    Fig 21: Locating Manual Valve Feed Tube
    G04656855Courtesy of FORD MOTOR CO.
  22. Lubricate the new O-ring seal with clean CVT transmission fluid and install the O-ring seal on the secondary feed tube.
    Fig 22: Locating O-Ring Seal
    G04656856Courtesy of FORD MOTOR CO.
  23. Install the secondary feed tube.
    Fig 23: Locating Secondary Feed Tube
    G04656857Courtesy of FORD MOTOR CO.
  24. From the opposite side of the case, install a new C-clip on the secondary feed tube.
    Fig 24: Locating C-Clip On Secondary Feed Tube
    G04656858Courtesy of FORD MOTOR CO.
  25. Position the new manual control lever seal in place.
    Fig 25: Locating Manual Control Lever Seal
    G04656859Courtesy of FORD MOTOR CO.
  26. Using the special tool, install the manual control lever seal.
    Fig 26: Identifying Special Tool (307-538)
    G04656860Courtesy of FORD MOTOR CO.
  27. Position the outer manual lever over the manual shaft. Install a new roll pin.
    Fig 27: Locating Roll Pin
    G04656861Courtesy of FORD MOTOR CO.
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