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Manual Transmission: Disassembly: Transaxle

Fig 1: Identifying Special Tools
G02739803Courtesy of FORD MOTOR CO.
Fig 2: Exploded View Of Transaxle Components (1 Of 2)
G02739804Courtesy of FORD MOTOR CO.
Fig 3: Exploded View Of Transaxle Components (2 Of 2)
G02739805Courtesy of FORD MOTOR CO.
  1. Clean the transaxle exterior with solvent before disassembly.
  2. Clean all removed parts (except sealed bearings) and all sealing surfaces with solvent, and dry with compressed air.
    3. 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. Failure to follow these instructions may result in personal injury.
  3. Clean out all holes and passages with compressed air and verify that there are no obstructions.
  4. Using the special tool, mount the transaxle to a bench.
    Fig 4: Mounting Transaxle To A Bench
    G02739806Courtesy of FORD MOTOR CO.
  5. Remove the clutch release fork and bearing.
    1. Remove the boot.
    2. Remove the clutch release fork and bearing.
    Fig 5: Removing Clutch Release Fork And Bearing
    G02739807Courtesy of FORD MOTOR CO.
  6. Remove the anchor bolt.
    Fig 6: Removing Anchor Bolt
    G02739808Courtesy of FORD MOTOR CO.
  7. Remove the park/neutral position (PNP) switch.
    Fig 7: Removing Park/Neutral Position (PNP) Switch
    G02739809Courtesy of FORD MOTOR CO.
  8. Remove the bolt and the vehicle speed sensor (VSS).
    Fig 8: Removing Vehicle Speed Sensor (VSS)
    G02739810Courtesy of FORD MOTOR CO.
  9. Rotate the transaxle 180 degrees.
  10. Remove the reversing lamp switch.
    Fig 9: Removing Reversing Lamp Switch
    G02739811Courtesy of FORD MOTOR CO.
  11. Remove the clutch slave cylinder line bracket.
    1. Remove the bolts.
    2. Remove the clutch slave cylinder line bracket.
    Fig 10: Removing Clutch Slave Cylinder Line Bracket
    G02739812Courtesy of FORD MOTOR CO.
  12. Shift the transaxle into first gear.
  13. Remove the case cover.
    1. Remove the bolts.
    2. Remove the case cover.
    Fig 11: Removing Case Cover
    G02739813Courtesy of FORD MOTOR CO.
    14. CAUTION: Do not reuse locknuts.
    Fig 12: Removing Input And Output Shaft Locknuts
    G02739814Courtesy of FORD MOTOR CO.
  14. Remove the input and output shaft locknuts and discard.
    1. Using the special tool, keep the input shaft from turning.
    2. Remove the input and output shaft locknuts and discard.
    15. CAUTION: The synchronizer blocking rings are not interchangeable. Make sure to keep them in the order that they were removed.
    Fig 13: Removing Reverse Synchronizer Blocking Ring
    G02739815Courtesy of FORD MOTOR CO.
  15. Remove the reverse synchronizer blocking ring.
  16. Remove and discard the reverse/fifth shift fork roll pin.
    Fig 14: Removing Reverse/Fifth Shift Fork Roll Pin
    G02739816Courtesy of FORD MOTOR CO.
  17. Remove the reverse/fifth shift fork and synchronizer hub assembly.
    Fig 15: Removing Reverse/Fifth Shift Fork And Synchronizer Hub Assembly
    G02739817Courtesy of FORD MOTOR CO.
  18. Remove the synchronizer blocking ring.
    Fig 16: Removing Synchronizer Blocking Ring
    G02739818Courtesy of FORD MOTOR CO.
  19. Remove the fifth speed cluster gear.
    Fig 17: Removing Fifth Speed Cluster Gear
    G02739819Courtesy of FORD MOTOR CO.
  20. Remove the fifth gear bushing.
    Fig 18: Removing Fifth Gear Bushing
    G02739820Courtesy of FORD MOTOR CO.
  21. Remove the fifth speed gear.
    Fig 19: Removing Fifth Speed Gear
    G02739821Courtesy of FORD MOTOR CO.
  22. Remove the reverse idler shaft lock bolt and shift rail guide bolt.
    Fig 20: Removing Reverse Idler Shaft Lock Bolt And Shift Rail Guide Bolt
    G02739822Courtesy of FORD MOTOR CO.
  23. Remove the bolt, spring, and ball.
    Fig 21: Removing Bolt, Spring, And Ball
    G02739823Courtesy of FORD MOTOR CO.
  24. Separate the transaxle case.
    1. Remove the 15 transaxle case bolts.
    2. Separate the transaxle case.
    Fig 22: Separating Transaxle Case
    G02739824Courtesy of FORD MOTOR CO.
  25. Remove the magnet.
    Fig 23: Removing Magnet
    G02739825Courtesy of FORD MOTOR CO.
  26. Remove the reverse idler gear.
    1. Remove the reverse idler gear shaft.
    2. Remove the reverse idler gear.
    Fig 24: Removing Reverse Idler Gear
    G02739826Courtesy of FORD MOTOR CO.
  27. Remove the shift gate bolt.
    Fig 25: Removing Shift Gate Bolt
    G02739827Courtesy of FORD MOTOR CO.
  28. Remove the shift control shaft and shift gate.
    1. Remove the shift control shaft.
    2. Remove the shift gate.
    Fig 26: Removing Shift Control Shaft And Shift Gate
    G02739828Courtesy of FORD MOTOR CO.
  29. Remove the shift lever shaft roll pin.
    Fig 27: Removing Shift Lever Shaft Roll Pin
    G02739829Courtesy of FORD MOTOR CO.
  30. Remove the shift lever shaft and shift fork selector lever.
    1. Remove the shift lever shaft.
    2. Remove the shift fork selector lever.
    Fig 28: Removing Shift Fork Selector Lever
    G02739830Courtesy of FORD MOTOR CO.
  31. Shift into second and fourth gears.
    32. WARNING: When removing the gear shifter fork and main shift control 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. Failure to follow these instructions may result in personal injury.
    Fig 29: Removing Gear Shifter Fork And Main Shift Control Shaft Assembly
    G02739831Courtesy of FORD MOTOR CO.
  32. Remove the gear shifter fork and main shift control shaft assembly, detent ball and spring.
  33. Remove the output and input shafts as an assembly.
    Fig 30: Removing Output And Input Shafts As An Assembly
    G02739832Courtesy of FORD MOTOR CO.
  34. Remove the differential.
    Fig 31: Removing Differential
    G02739833Courtesy of FORD MOTOR CO.
    35. NOTE: Flywheel housing side shown, transaxle case side similar.
    Fig 32: Removing Input Shaft Bearing Cups
    G02739834Courtesy of FORD MOTOR CO.
  35. Remove the input shaft bearing cups.
  36. Using the special tools, remove the input shaft seal.
    Fig 33: Removing Input Shaft Seal
    G02739835Courtesy of FORD MOTOR CO.
    37. NOTE: Flywheel housing side shown, transaxle case side similar.
    Fig 34: Removing Output Shaft Bearing Cups
    G02739836Courtesy of FORD MOTOR CO.
  37. Remove the output shaft bearing cups.
  38. Remove the funnel.
    Fig 35: Removing Funnel
    G02739837Courtesy of FORD MOTOR CO.
  39. Remove the shift control selector plate and spacer.
    1. Remove the bolts.
    2. Remove the shift control selector plate and spacer.
    Fig 36: Removing Shift Control Selector Plate And Spacer
    G02739838Courtesy of FORD MOTOR CO.
  40. Remove the shift control shaft selector lever.
    1. Remove the bolt.
    2. Remove the shift control shaft selector lever.
    Fig 37: Removing Shift Control Shaft Selector Lever
    G02739839Courtesy of FORD MOTOR CO.
  41. Remove and discard the roll pin.
    Fig 38: Removing And Discard Roll Pin
    G02739840Courtesy of FORD MOTOR CO.
  42. Remove the shift control shaft assembly.
    Fig 39: Removing Shift Control Shaft Assembly
    G02739841Courtesy of FORD MOTOR CO.
  43. Using the special tool, remove the shift control shaft seal.
    Fig 40: Removing Shift Control Shaft Seal
    G02739842Courtesy of FORD MOTOR CO.
  44. Remove the vent tube.
    1. Remove the bolts.
    2. Remove the vent tube.
    Fig 41: Removing Vent Tube
    G02739843Courtesy of FORD MOTOR CO.
    45. NOTE: Flywheel housing side shown, transaxle case side similar.
    Fig 42: Removing Differential Bearing Cups
    G02739844Courtesy of FORD MOTOR CO.
  45. Using the special tools, remove the differential bearing cups.
  46. Remove and discard the reverse lever roll pin.
    Fig 43: Removing Reverse Lever Roll Pin
    G02739845Courtesy of FORD MOTOR CO.
  47. Remove the reverse lever shaft.
    1. Remove the reverse lever shaft.
    2. Remove the reverse lever.
    Fig 44: Removing Reverse Lever Shaft
    G02739846Courtesy of FORD MOTOR CO.
    48. NOTE: Transaxle case side shown, flywheel housing side similar.
    Fig 45: Removing Halfshaft Seals
    G02739847Courtesy of FORD MOTOR CO.
  48. Using the special tool, remove the halfshaft seals.
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