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Manual Transmission: Assembly: Transaxle

Fig 1: Identifying Special Tools
G02739958Courtesy of FORD MOTOR CO.
CAUTION: 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. Using the special tool, install the input shaft seal.
    Fig 2: Installing Input Shaft Seal
    G02739959Courtesy of FORD MOTOR CO.
  2. Install the input shaft bearing cup into the flywheel housing.
    Fig 3: Installing Input Shaft Bearing Cup Into Flywheel Housing
    G02739960Courtesy of FORD MOTOR CO.
  3. Install the input shaft.
    Fig 4: Installing Input Shaft
    G02739961Courtesy of FORD MOTOR CO.
  4. Position the bearing cup onto the bearing.
    Fig 5: Positioning Bearing Cup Onto Bearing
    G02739962Courtesy of FORD MOTOR CO.
  5. Position the special tools.
    Fig 6: Positioning Special Tools
    G02739963Courtesy of FORD MOTOR CO.
  6. Install the transaxle case.
    1. Position the transaxle case.
    2. Install the bolts.
    Fig 7: Installing Transaxle Case
    G02739964Courtesy of FORD MOTOR CO.
  7. Mount a dial indicator to the transaxle case.
    Fig 8: Mounting Dial Indicator To Transaxle Case
    G02739965Courtesy of FORD MOTOR CO.
  8. Rotate the input shaft to seat the bearings.
  9. Zero the dial indicator.
    Fig 9: Identifying Dial Indicator
    G02739966Courtesy of FORD MOTOR CO.
    10. CAUTION: The shaft must be lifted equally on both sides or it may cock to one side, resulting in an incorrect reading.
    Fig 10: Checking Input Shaft End Play
    G02739967Courtesy 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 11: Input Shaft Shim Size Formula
    G02050047Courtesy of FORD MOTOR CO.
    12. 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 12: Installing Shim
    G02739968Courtesy of FORD MOTOR CO.
  15. Using the special tools, install the input shaft bearing cup.
    Fig 13: Installing Input Shaft Bearing Cup
    G02739969Courtesy of FORD MOTOR CO.
  16. Install the funnel.
    Fig 14: Installing Funnel
    G02739970Courtesy of FORD MOTOR CO.
  17. Using the special tools, install the output shaft bearing cup.
    Fig 15: Installing Output Shaft Bearing Cup
    G02739971Courtesy of FORD MOTOR CO.
  18. Install the output shaft.
    Fig 16: Installing Output Shaft
    G02739972Courtesy of FORD MOTOR CO.
  19. Position the bearing cup onto the bearing.
    Fig 17: Positioning Bearing Cup Onto Bearing
    G02739973Courtesy of FORD MOTOR CO.
    20. NOTE: The gauge halves must be turned to eliminate any gap between them.
    Fig 18: Positioning Special Tools
    G02739974Courtesy of FORD MOTOR CO.
  20. Position the special tools.
  21. Install the transaxle case.
    1. Position the transaxle case.
    2. Install the bolts.
    Fig 19: Installing Transaxle Case
    G02739975Courtesy of FORD MOTOR CO.
  22. Install a dial indicator on the transaxle case.
    Fig 20: Installing Dial Indicator On Transaxle Case
    G02739976Courtesy of FORD MOTOR CO.
  23. Rotate the output shaft to seat the bearings.
  24. Zero the dial indicator.
    Fig 21: Identifying Dial Indicator
    G02739977Courtesy of FORD MOTOR CO.
    25. CAUTION: The shaft must be lifted equally on both sides or it may cock to one side, resulting in an incorrect reading.
    Fig 22: Checking Output Shaft End Play
    G02739978Courtesy 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 23: Output Shaft Shim Size Formula
    G02050047Courtesy of FORD MOTOR CO.
    27. 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 24: Installing Shim
    G02739979Courtesy of FORD MOTOR CO.
  30. Using the special tools, install the output shaft bearing cup.
    Fig 25: Installing Output Shaft Bearing Cup
    G02739980Courtesy of FORD MOTOR CO.
  31. Using the special tools, install the differential bearing cup into the flywheel housing.
    Fig 26: Installing Differential Bearing Cup Into Flywheel Housing
    G02739981Courtesy of FORD MOTOR CO.
  32. Install the differential.
    Fig 27: Installing Differential
    G02739982Courtesy of FORD MOTOR CO.
  33. Position the bearing cup onto the bearing.
    Fig 28: Positioning Bearing Cup Onto Bearing
    G02739983Courtesy of FORD MOTOR CO.
    34. NOTE: The gauge halves must be turned to eliminate any gap between them.
    Fig 29: Positioning Special Tools
    G02739984Courtesy of FORD MOTOR CO.
  34. Position the special tools.
  35. Install the transaxle case.
    1. Position the transaxle case.
    2. Install the bolts.
    Fig 30: Installing Transaxle Case
    G02739985Courtesy of FORD MOTOR CO.
  36. Using the special tool, adjust gauge until the free play is removed. Turn gauge back together.
    Fig 31: Locating Gauge
    G02739986Courtesy of FORD MOTOR CO.
  37. Insert the special tool through the transaxle case and engage the differential pinion shaft.
    Fig 32: Inserting Special Tool Through Transaxle Case
    G02739987Courtesy of FORD MOTOR CO.
  38. Using the special tools, adjust gauge until the differential rotation is within specification.
    Fig 33: Adjusting Gauge
    G02739988Courtesy of FORD MOTOR CO.
  39. Measure the gap in the special tool.
    Fig 34: Measuring Gap In Special Tool
    G02739989Courtesy of FORD MOTOR CO.
  40. Add 0.15 mm (0.0059 in) to the measurement to achieve the final clearance.
    41. CAUTION: Do not use more than two differential shims.
  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.
    DIFFERENTIAL BEARING SHIMS SPECIFICATIONS

    Part Number Shim Thickness
    E92Z-4067-A 0.10 mm (0.004 in)
    E92Z-4067-D 0.15 mm (0.006 in)
    E92Z-4067-F 0.20 mm (0.008 in)
    E92Z-4067-G 0.25 mm (0.010 in)
    E92Z-4067-H 0.30 mm (0.012 in)
    E92Z-4067-J 0.35 mm (0.014 in)
    E92Z-4067-K 0.40 mm (0.016 in)
    E92Z-4067-L 0.45 mm (0.018 in)
    E92Z-4067-N 0.50 mm (0.020 in)
    E92Z-4067-P 0.55 mm (0.022 in)
    E92Z-4067-Q 0.60 mm (0.024 in)
    E92Z-4067-R 0.65 mm (0.026 in)
    E92Z-4067-S 0.70 mm (0.028 in)
    E92Z-4067-T 0.75 mm (0.030 in)
    E92Z-4067-U 0.80 mm (0.032 in)
    E92Z-4067-V 0.85 mm (0.034 in)
    E92Z-4067-W 0.90 mm (0.036 in)
    E92Z-4067-X 0.95 mm (0.038 in)
    E92Z-4067-Y 1.00 mm (0.040 in)
    E92Z-4067-Z 1.05 mm (0.042 in)
    E92Z-4067-AA 1.10 mm (0.044 in)
    E92Z-4067-AB 1.15 mm (0.046 in)
    E92Z-4067-AC 1.20 mm (0.048 in)
  42. Remove the transaxle case, special tools, bearing cup, and differential.
  43. Install the differential bearing cup shim(s) into the transaxle case.
    Fig 35: Installing Differential Bearing Cup Shim(s) Into Transaxle Case
    G02739990Courtesy of FORD MOTOR CO.
  44. Using the special tools, install the differential bearing cup into the transaxle case.
    Fig 36: Installing Differential Bearing Cup Into Transaxle Case
    G02739991Courtesy of FORD MOTOR CO.
    45. NOTE: Transaxle case side shown, flywheel housing side similar.
    Fig 37: Installing Halfshaft Seals
    G02739992Courtesy 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 38: Installing Reverse Lever And Shaft
    G02739993Courtesy of FORD MOTOR CO.
  47. Install the reverse lever roll pin.
    Fig 39: Installing Reverse Lever Roll Pin
    G02739994Courtesy of FORD MOTOR CO.
  48. Install the vent tube and the vent tube bolts.
    Fig 40: Installing Vent Tube And Vent Tube Bolts
    G02739995Courtesy of FORD MOTOR CO.
  49. Using the special tool, install the shift control shaft seal.
    Fig 41: Installing Shift Control Shaft Seal
    G02739996Courtesy of FORD MOTOR CO.
    50. NOTE: Install the boot with the drain hole facing downward when installed in the vehicle.
    Fig 42: Installing Shift Control Shaft Assembly
    G02739997Courtesy of FORD MOTOR CO.
  50. Install the shift control shaft assembly.
  51. Install a new roll pin.
    Fig 43: Installing Roll Pin
    G02739998Courtesy 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 44: Installing Shift Control Shaft Selector Lever
    G02739999Courtesy 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 45: Installing Shift Control Selector Plate And Spacer
    G02740000Courtesy of FORD MOTOR CO.
  54. Install the differential.
    Fig 46: Installing Differential
    G02740001Courtesy of FORD MOTOR CO.
  55. Install the output and input shafts as an assembly.
    Fig 47: Installing Output And Input Shafts As An Assembly
    G02740002Courtesy of FORD MOTOR CO.
  56. Install the gear shifter fork and main shift control shaft assembly, spring and detent ball.
    Fig 48: Installing Gear Shifter Fork And Main Shift Control Shaft Assembly
    G02740003Courtesy 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 49: Installing Shift Lever Shaft And Shift Fork Selector Lever
    G02740004Courtesy of FORD MOTOR CO.
  59. Install the shift lever shaft roll pin.
    Fig 50: Installing Shift Lever Shaft Roll Pin
    G02740005Courtesy 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 51: Installing Shift Control Shaft And Shift Gate
    G02740006Courtesy of FORD MOTOR CO.
  61. Install the shift gate bolt.
    Fig 52: Installing Shift Gate Bolt
    G02740007Courtesy of FORD MOTOR CO.
  62. Install the reverse idler gear.
    1. Install reverse idler gear.
    2. Install reverse idler gear shaft.
    Fig 53: Installing Reverse Idler Gear
    G02740008Courtesy of FORD MOTOR CO.
  63. Install the magnet.
    Fig 54: Installing Magnet
    G02740009Courtesy 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 55: Positioning Gear Selector Arm And Reverse Idler Gear Shaft
    G02740010Courtesy of FORD MOTOR CO.
    65. 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 56: Installing Transaxle Case
    G02740011Courtesy of FORD MOTOR CO.
  67. Install the lock bolt, spring, and ball.
    Fig 57: Installing Lock Bolt, Spring, And Ball
    G02740012Courtesy of FORD MOTOR CO.
    68. CAUTION: Make sure that the shift rail guide bolt is in the groove of the shift rail.
    Fig 58: Torque Specifications Of Reverse Idler Shaft Lock Bolt & Shift Rail Guild Bolt
    G02740013Courtesy of FORD MOTOR CO.
  68. Install the reverse idler shaft lock bolt and shift rail guide bolt.
  69. Install the fifth speed gear.
    Fig 59: Installing Fifth Speed Gear
    G02740014Courtesy of FORD MOTOR CO.
  70. Install the fifth gear bushing.
    Fig 60: Installing Fifth Gear Bushing
    G02740015Courtesy of FORD MOTOR CO.
  71. Measure the clearance between the reverse/fifth synchronizer sleeve and its shift fork.
    Fig 61: Measuring Clearance Between Reverse/Fifth Synchronizer Sleeve
    G02740016Courtesy of FORD MOTOR CO.
  72. Install the fifth speed cluster gear.
    Fig 62: Installing Fifth Speed Cluster Gear
    G02740017Courtesy of FORD MOTOR CO.
    73. CAUTION: The synchronizer blocking rings are not interchangeable. Make sure to keep them in the order that they were removed.
    Fig 63: Installing Synchronizer Blocking Ring
    G02740018Courtesy of FORD MOTOR CO.
  73. Install the synchronizer blocking ring.
  74. Install the reverse/fifth shift fork and synchronizer hub assembly.
    Fig 64: Installing Reverse/Fifth Shift Fork And Synchronizer Hub Assembly
    G02740019Courtesy of FORD MOTOR CO.
  75. Install a new reverse/fifth shift fork roll pin.
    Fig 65: Installing Reverse/Fifth Shift Fork Roll Pin
    G02740020Courtesy of FORD MOTOR CO.
    76. CAUTION: The synchronizer blocking rings are not interchangeable. Make sure to install them in the order that they were removed.
    Fig 66: Installing Reverse Synchronizer Blocking Ring
    G02740021Courtesy of FORD MOTOR CO.
  76. Install the reverse synchronizer blocking ring.
  77. Shift the transaxle into first gear.
    78. CAUTION: Do not reuse locknuts.
    CAUTION: Stake the locknuts.
    Fig 67: Installing Input And Output Shaft Locknuts
    G02740022Courtesy of FORD MOTOR CO.
  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.
    79. 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 68: Installing Case Cover
    G02740023Courtesy 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 69: Installing Clutch Slave Cylinder Line Bracket
    G02740024Courtesy of FORD MOTOR CO.
  82. Install the reversing lamp switch.
    Fig 70: Installing Reversing Lamp Switch
    G02740025Courtesy of FORD MOTOR CO.
  83. Rotate the transaxle 180 degrees.
  84. Install the park/neutral position (PNP) switch.
    Fig 71: Installing Park/Neutral Position (PNP) Switch
    G02740026Courtesy of FORD MOTOR CO.
  85. Install the anchor bolt.
    Fig 72: Installing Anchor Bolt
    G02740027Courtesy 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 73: Installing Clutch Release Fork And Bearing
    G02740028Courtesy of FORD MOTOR CO.
  87. Remove the transaxle from the special tool.
    Fig 74: Removing Transaxle From Special Tool
    G02740029Courtesy of FORD MOTOR CO.
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