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Manual Transmission: Disassembly: Transaxle

Special Tools

Illustration Tool Name Tool Number
GF0000940
 Holding Fixture 307-003 (T57L-500-B)
GF0029965
 Torque Adapter 308-160 (T88C-7025-GH)
  1. Clean the transaxle exterior with solvent before disassembly.
  2. Clean all removed parts and all sealing surfaces with solvent, and dry with compressed air.
  3. Clean out all holes and passages with compressed air and verify that there are no obstructions.
  4. Mount the transaxle to the special tool.
    5. Fig 1: Identifying Special Tool (307-003) And Transaxle
    GF0029966Courtesy of FORD MOTOR CO.
  5. Remove the drain plug and drain the transaxle.
  6. Remove the clutch release fork and bearing.
    1. Remove the boot.
    2. Remove the clutch release fork and bearing.
    7. Fig 2: Identifying Boot, Clutch Release Fork And Bearing
    GF0029967Courtesy of FORD MOTOR CO.
  7. Remove the anchor bolt.
    8. Fig 3: Locating Anchor Bolt
    GF0029968Courtesy of FORD MOTOR CO.
  8. Remove the bolt and the vehicle speed sensor (VSS).
    9. Fig 4: Locating Vehicle Speed Sensor (VSS) Bolt
    GF0029969Courtesy of FORD MOTOR CO.
  9. Rotate the transaxle 180 degrees.
  10. Remove the reversing lamp switch.
    11. Fig 5: Locating Reversing Lamp Switch
    GF0029970Courtesy of FORD MOTOR CO.
  11. Shift the transaxle into the NEUTRAL position.
  12. Remove the 9 case cover bolts and the case cover.
    13. Fig 6: Locating Case Cover Bolts
    GF0029971Courtesy of FORD MOTOR CO.
    NOTE: Do not reuse lock nuts.
  13. Remove the input and output shaft lock nuts.
    1. Using the special tool, keep the input shaft from turning.
    2. Using a punch, release the locking tabs from the shafts. Remove and discard the input and output shaft lock nuts.
    14. Fig 7: Identifying Special Tool (308-160) And Input & Output Shaft Lock Nuts
    GF0029972Courtesy of FORD MOTOR CO.
  14. Remove and discard the reverse/5th shift fork roll pin.
    15. Fig 8: Locating Reverse/5th Shift Fork Roll Pin
    GF0029973Courtesy of FORD MOTOR CO.
  15. Remove the reverse/5th shift fork and synchronizer hub assembly.
    16. Fig 9: Locating Reverse/5th Shift Fork & Synchronizer Hub Assembly
    GF0029974Courtesy of FORD MOTOR CO.
  16. Remove the synchronizer blocking ring.
    17. Fig 10: Locating Synchronizer Blocking Ring
    GF0029975Courtesy of FORD MOTOR CO.
  17. Remove the 5th speed cluster gear.
    18. Fig 11: Locating 5th Speed Cluster Gear
    GF0029976Courtesy of FORD MOTOR CO.
  18. Remove the 5th gear bushing.
    19. Fig 12: Locating 5th Gear Bushing
    GF0029977Courtesy of FORD MOTOR CO.
  19. Remove the 5th speed gear.
    20. Fig 13: Locating 5th Speed Gear
    GF0029978Courtesy of FORD MOTOR CO.
  20. Remove the reverse idler shaft lock bolt and shift rail guide bolt.
    21. Fig 14: Locating Reverse Idler Shaft Lock Bolt And Shift Rail Guide Bolt
    GF0029979Courtesy of FORD MOTOR CO.
  21. Remove the bolt, spring and ball.
    22. Fig 15: Identifying Bolt, Spring And Ball
    GF0029980Courtesy of FORD MOTOR CO.
  22. Remove the 15 transaxle case bolts and separate the transaxle case.
    • After separating the transaxle cases, position the removed case on its side.
  23. Remove the funnel bolt and the funnel.
    24. Fig 16: Locating Funnel
    GF0029981Courtesy of FORD MOTOR CO.
  24. Remove the magnet.
    25. Fig 17: Locating Magnet
    GF0029982Courtesy of FORD MOTOR CO.
  25. Remove the reverse idler gear and the reverse idler gear shaft.
    26. Fig 18: Locating Reverse Idler Gear And Reverse Idler Gear Shaft
    GF0029983Courtesy of FORD MOTOR CO.
  26. Remove the shift gate bolt.
    27. Fig 19: Locating Shift Gate Bolt
    GF0029984Courtesy of FORD MOTOR CO.
  27. Remove the shift control shaft and shift gate.
    1. Remove the shift control shaft.
    2. Remove the shift gate.
    28. Fig 20: Identifying Shift Control Shaft And Shift Gate
    GF0029985Courtesy of FORD MOTOR CO.
  28. Remove the shift lever shaft roll pin, then remove the shift lever shaft and shift fork selector lever.
    • Use a screwdriver to aid removal.
    29. Fig 21: Locating Shift Lever Shaft Roll Pin
    GF0029986Courtesy of FORD MOTOR CO.
  29. Move the shift forks upward into 2nd and 4th gears.
    30. Fig 22: Moving Shift Forks Upward Into 2nd And 4th Gears
    GF0029987Courtesy of FORD MOTOR CO.
  30. Remove the gear shifter fork and main shift control shaft assembly.
    • Lift the rail out of the rail pocket.
    31. Fig 23: Identifying Gear Shifter Fork & Main Shift Control Shaft Assembly
    GF0029988Courtesy of FORD MOTOR CO.
  31. Remove the shift detent and spring.
    32. Fig 24: Locating Spring And Shift Detent
    GF0029989Courtesy of FORD MOTOR CO.
  32. Remove the shift lever roll pin.
    33. Fig 25: Locating Shift Lever Roll Pin
    GF0029990Courtesy of FORD MOTOR CO.
  33. Remove the reverse shift lever shaft and the reverse lever.
    34. Fig 26: Locating Reverse Shift Lever Shaft And Reverse Lever
    GF0029991Courtesy of FORD MOTOR CO.
  34. Remove the output and input shafts as an assembly.
    35. Fig 27: Locating Output And Input Shafts Assembly
    GF0029992Courtesy of FORD MOTOR CO.
  35. Remove the differential.
    36. Fig 28: Locating Differential
    GF0029993Courtesy of FORD MOTOR CO.
  36. For further disassembly of the transaxle case, refer to Transaxle Case .
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