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Manual Transaxle/Transmission: Assembly: Transaxle: Assembly

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 1: Installing Input Shaft Bearing Cup Into Flywheel Housing
    G01372513Courtesy of FORD MOTOR CO.
  2. Install the input shaft.
    Fig 2: Installing Input Shaft
    G01372514Courtesy of FORD MOTOR CO.
  3. Position the bearing cup onto the bearing, then install Shim Selection Gauge on the bearing cup.
    Fig 3: Installing Shim Selection Gauge On Bearing Cup
    G01372515Courtesy of FORD MOTOR CO.
  4. Position collars onto the flywheel housing.
    Fig 4: Positioning Collars Onto Flywheel Housing
    G01372516Courtesy of FORD MOTOR CO.
  5. Position the transaxle case on collars and install the bolts.
    Fig 5: Positioning Transaxle Case On Collars
    G01372517Courtesy of FORD MOTOR CO.
  6. Mount Dial Indicator and Dial Indicator Bracketry on the transaxle case.
    Fig 6: Mounting Dial Indicator And Dial Indicator Bracketry On Transaxle Case
    G01372518Courtesy of FORD MOTOR CO.
  7. Rotate the input shaft to seat the bearings.
  8. Zero Dial Indicator.
    Fig 7: Zeroing Dial Indicator
    G01372519Courtesy 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 8: Checking End Play
    G01372520Courtesy 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 below to select the correct shim size.
    Fig 9: Shim Size Chart
    G01372521Courtesy 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 10: Installing Shim
    G01372522Courtesy of FORD MOTOR CO.
  14. Use (A) Driver Handle and (B) Bearing Cup Replacer to install the (C) input shaft bearing cup.
    Fig 11: Installing Input Shaft Bearing Cup
    G01372523Courtesy of FORD MOTOR CO.
  15. Install the fifth shaft funnel and the output shaft bearing cup.
    1. Install the fifth shaft funnel.
    2. Install the output shaft bearing cup.
    Fig 12: Installing Fifth Shaft Funnel And Output Shaft Bearing Cup
    G01372524Courtesy of FORD MOTOR CO.
  16. Install the output shaft.
    Fig 13: Installing Output Shaft
    G01372525Courtesy of FORD MOTOR CO.
  17. Position the bearing cup onto the bearing.
    Fig 14: Positioning Bearing Cup Onto Bearing
    G01372526Courtesy of FORD MOTOR CO.
    18. NOTE: The gauge halves must be turned to eliminate any gap between them.
    Fig 15: Positioning Shim Selection Gauge On Bearing Cup
    G01372527Courtesy of FORD MOTOR CO.
  18. Position Shim Selection Gauge on the bearing cup.
  19. Position collars onto the flywheel housing.
    Fig 16: Positioning Collars Onto Flywheel Housing
    G01372528Courtesy of FORD MOTOR CO.
  20. Position the transaxle case on collars and install the bolts.
    Fig 17: Positioning Transaxle Case On Collars
    G01372529Courtesy of FORD MOTOR CO.
  21. Mount Dial Indicator and Dial Indicator Bracketry on the transaxle case.
    Fig 18: Mounting Dial Indicator And Dial Indicator Bracketry On Transaxle Case
    G01372530Courtesy of FORD MOTOR CO.
  22. Rotate the output shaft to seat the bearings.
  23. Zero Dial Indicator.
    Fig 19: Zeroing Dial Indicator
    G01372531Courtesy 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 20: Checking End Play
    G01372532Courtesy 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 21: Shim Size Chart
    G01372533Courtesy 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.
    Fig 22: Removing Transaxle Case, Gauge, Bearing Cup And Output Shaft
    G01372534Courtesy of FORD MOTOR CO.
  28. Install the shim.
    Fig 23: Installing Shim
    G01372535Courtesy of FORD MOTOR CO.
  29. Use (A) Driver Handle and (B) Bearing Cup Replacer to install the (C) output shaft bearing cup.
    Fig 24: Installing Output Shaft Bearing Cup
    G01372536Courtesy 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.
  31. Install the differential.
    Fig 25: Installing Differential
    G01372537Courtesy of FORD MOTOR CO.
  32. Position the bearing cup onto the bearing.
    Fig 26: Positioning Bearing Cup Onto Bearing
    G01372538Courtesy of FORD MOTOR CO.
    33. NOTE: The gauge halves must be turned to eliminate any gap between them.
    Fig 27: Placing Shim Selection Gauge Onto Bearing Cup
    G01372539Courtesy of FORD MOTOR CO.
  33. Place Shim Selection Gauge onto the bearing cup.
  34. Position collars on the flywheel housing.
    Fig 28: Positioning Collars On Flywheel Housing
    G01372540Courtesy of FORD MOTOR CO.
  35. Position the transaxle case on collars and install the bolts.
    Fig 29: Positioning Transaxle Case On Collars
    G01372541Courtesy 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 30: Adjusting Shim Selection Gauge
    G01372542Courtesy of FORD MOTOR CO.
  37. Insert Differential Rotator through the transaxle case and engage the differential pinion shaft.
    Fig 31: Inserting Differential Rotator Through Transaxle Case And Engage Differential Pinion Shaft
    G01372543Courtesy of FORD MOTOR CO.
  38. Use pins to adjust Shim Selection Gauge until the differential rotation is within specification.
    Fig 32: Adjusting Shim Selection Gauge
    G01372544Courtesy of FORD MOTOR CO.
  39. Use a feeler gauge to measure the gap in Shim Selection Gauge.
    Fig 33: Measuring Gap In Shim Selection Gauge
    G01372545Courtesy 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 34: Differential Bearing Shims Chart
    G01372546Courtesy 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, gauge, bearing cup, and differential.
  43. Install the differential shim(s) into the transaxle case.
    Fig 35: Installing Differential Shim(s) Into Transaxle Case
    G01372547Courtesy 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 36: Installing Differential Bearing Cup Into Transaxle Case
    G01372548Courtesy of FORD MOTOR CO.
  45. Use Differential Seal Replacer to install the differential seals.
    Fig 37: Installing Differential Seals
    G01372549Courtesy of FORD MOTOR CO.
  46. Use Bell Housing Seal Replacer to install the input shaft oil seal.
    Fig 38: Installing Input Shaft Oil Seal
    G01372550Courtesy of FORD MOTOR CO.
  47. Install the park/neutral position (PNP) switch and gasket.
    Fig 39: Installing Park/Neutral Position Switch And Gasket
    G01372551Courtesy of FORD MOTOR CO.
  48. Install the reverse lever and shaft.
    1. Install the reverse lever.
    2. Install the reverse lever shaft.
    Fig 40: Installing Reverse Lever & Shaft
    G01372552Courtesy of FORD MOTOR CO.
  49. Install the reverse lever roll pin.
    Fig 41: Installing Reverse Lever Roll Pin
    G01372553Courtesy of FORD MOTOR CO.
  50. Install the vent tube and the vent tube bolts.
    Fig 42: Installing Vent Tube And Vent Tube Bolts
    G01372554Courtesy of FORD MOTOR CO.
  51. Use (A) Shift Lever Seal Replacer to install the (B) shift shaft seal.
    Fig 43: Installing Shift Shaft Seal
    G01372555Courtesy of FORD MOTOR CO.
    52. NOTE: Install the boot with the drain hole facing downward when installed in the vehicle.
    Fig 44: Installing Shift Control Shaft Assembly
    G01372556Courtesy of FORD MOTOR CO.
  52. Install the shift control shaft assembly.
  53. Install the shift control selector roll pin.
    Fig 45: Installing Shift Control Selector Roll Pin
    G01372557Courtesy of FORD MOTOR CO.
  54. Install the shift control shaft selector lever and bolt.
    1. Position the shift control shaft selector lever.
    2. Install the shift control shaft selector lever bolt.
    Fig 46: Installing Shift Control Shaft Selector Lever & Bolt
    G01372558Courtesy of FORD MOTOR CO.
  55. Install the differential.
    Fig 47: Installing Differential
    G01372559Courtesy of FORD MOTOR CO.
  56. Install the output and input shafts as an assembly.
    Fig 48: Installing Output And Input Shafts
    G01372560Courtesy of FORD MOTOR CO.
  57. Install the shift fork shaft assembly, spring and detent ball.
    Fig 49: Installing Shift Fork Shaft Assembly, Spring And Detent Ball
    G01372561Courtesy of FORD MOTOR CO.
  58. Install the shift control shaft and shift fork selector lever.
    1. Install the shift fork selector lever.
    2. Install the shift control shaft.
    Fig 50: Installing Shift Control Shaft And Shift Fork Selector Lever
    G01372562Courtesy of FORD MOTOR CO.
  59. Install the roll pin.
    Fig 51: Installing Roll Pin
    G01372563Courtesy of FORD MOTOR CO.
  60. Install the shift control rod.
    1. Install the shift gate.
    2. Install the shift control rod.
    Fig 52: Installing Shift Control Rod
    G01372564Courtesy of FORD MOTOR CO.
  61. Install the shift gate bolt.
    Fig 53: Installing Shift Gate Bolt
    G01372565Courtesy of FORD MOTOR CO.
  62. Install the reverse idler shaft and gear.
    1. Install reverse gear.
    2. Install reverse idler shaft.
    Fig 54: Installing Reverse Idler Shaft
    G01372566Courtesy of FORD MOTOR CO.
  63. Install the magnet.
    Fig 55: Installing Magnet
    G01372567Courtesy of FORD MOTOR CO.
  64. Position the gear selector arm and reverse idler shaft.
    1. Align the end of the gear selector interlock sleeve with the gear selector arm.
    2. Face the reverse idler shaft hole in the direction shown.
    Fig 56: Positioning Gear Selector Arm And Reverse Idler Shaft
    G01372568Courtesy of FORD MOTOR CO.
    65. NOTE: The transaxle case must be installed within four minutes after applying Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4.
  65. Apply a small bead of Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4 to the transaxle mating surface.
  66. Install the transaxle case and bolts.
    1. Install the transaxle case.
    2. Install the thirteen bolts.
    Fig 57: Installing Transaxle Case And Bolts
    G01372569Courtesy of FORD MOTOR CO.
  67. Position the transaxle mount bracket and install the bolts.
    Fig 58: Installing Transaxle Mount Bracket And Bolts
    G01372570Courtesy of FORD MOTOR CO.
  68. Install the backup lamp switch.
    Fig 59: Installing Backup Lamp Switch
    G01372571Courtesy of FORD MOTOR CO.
  69. Install the lock bolt, spring, and ball.
    Fig 60: Installing Lock Bolt, Spring, And Ball
    G01372572Courtesy of FORD MOTOR CO.
    70. NOTE: Ensure that the bolt is in the groove of the shift rail.
    Fig 61: Installing Shift Rail Guide Bolt
    G01372573Courtesy of FORD MOTOR CO.
  70. Install the shift rail guide bolt.
  71. Install the reverse idler shaft lock bolt.
    Fig 62: Installing Reverse Idler Shaft Lock Bolt
    G01372574Courtesy of FORD MOTOR CO.
  72. Install the fifth gear and the output shaft fifth gear spacer.
    1. Install fifth gear.
    2. Install the output shaft fifth gear spacer.
    Fig 63: Installing Fifth Gear And Output Shaft Fifth Gear Spacer
    G01372575Courtesy of FORD MOTOR CO.
  73. Install the fifth gear bushing.
    Fig 64: Installing Fifth Gear Bushing
    G01372576Courtesy of FORD MOTOR CO.
  74. Measure the clearance between the fifth/reverse synchronizer sleeve and its shift fork.
    Fig 65: Measuring Clearance Between Fifth/Reverse Synchronizer Sleeve And Shift Fork
    G01372577Courtesy of FORD MOTOR CO.
  75. Install the input shaft fifth gear.
    Fig 66: Installing Input Shaft Fifth Gear
    G01372578Courtesy of FORD MOTOR CO.
    76. CAUTION: The synchronizer blocking rings are not interchangeable. Install the fifth gear and the output shaft fifth gear spacer. Be sure to keep them in the order that they were removed.
    Fig 67: Installing Synchronizer Blocking Ring
    G01372579Courtesy of FORD MOTOR CO.
  76. Install the synchronizer blocking ring.
  77. Install the fifth/reverse shift fork and synchronizer hub assembly.
    Fig 68: Installing Fifth/Reverse Shift Fork And Synchronizer Hub Assembly
    G01372580Courtesy of FORD MOTOR CO.
  78. Install the shift fork roll pin.
    Fig 69: Installing Shift Fork Roll Pin
    G01372581Courtesy of FORD MOTOR CO.
    79. CAUTION: The synchronizer blocking rings are not interchangeable. Be sure to keep them in the order that they were removed.
    Fig 70: Installing Synchronizer Blocking Ring
    G01372582Courtesy of FORD MOTOR CO.
  79. Install the synchronizer blocking ring.
  80. Install the reverse synchronizer blocking ring retainer assembly.
    1. Install the retainer.
    2. Install the spacer.
    Fig 71: Installing Reverse Synchronizer Blocking Ring Retainer Assembly
    G01372583Courtesy of FORD MOTOR CO.
  81. Shift the transaxle into first gear.
    82. CAUTION: Do not reuse locknuts.
    CAUTION: Stake the locknuts.
    Fig 72: Installing Input And Output Locknuts
    G01372584Courtesy of FORD MOTOR CO.
  82. Use Input Shaft Holder to install the input and output locknuts.
    83. NOTE: The case cover must be installed within four minutes after applying Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4.
  83. Apply a small bead of Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4 to the case and cover mating surface.
  84. Install the case cover and bolts.
    1. Install the case cover.
    2. Install the bolts.
    Fig 73: Installing Case Cover And Bolts
    G01372585Courtesy of FORD MOTOR CO.
  85. Remove the transaxle from Bench Mounted Holding Fixture.
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