Disassembly And Assembly: Transaxle: Assembly

Install the hollow input shaft onto the inner input shaft.

Fig 1: Installing Hollow Input Shaft On Inner Input Shaft
Courtesy of FORD MOTOR CO.
NOTE: If the clearance is less than the minimum measurement stated in the SPECIFICATIONS , install a new shift fork.

Using a suitable feeler gauge, measure the clearance between the shift fork and synchronizer hub sleeve in various places around the circumference.

Fig 2: Measuring Clearance Between Shift Fork And Synchronizer Hub Sleeve Using Feeler Gauge
Courtesy of FORD MOTOR CO.
NOTE: Apply pressure on the synchronizer ring while taking the measurements.

NOTE: If the clearance is less than the minimum measurement stated in the SPECIFICATIONS , install a new output shaft assembly.

Using a suitable feeler gauge, measure the clearance between the synchronizer ring and gear in various places around the circumference.

Fig 3: Measuring Clearance Between Synchronizer Ring And Gear Using Feeler Gauge
Courtesy of FORD MOTOR CO.
NOTE: Make sure the synchronizers are in the neutral position.

Install output shaft 2 assembly on the special tool.

Fig 4: Installing Output Shaft 2 Assembly On Special Tool
Courtesy of FORD MOTOR CO.
Install the input shaft assembly on the special tool.

Fig 5: Installing Input Shaft Assembly On Special Tool
Courtesy of FORD MOTOR CO.
NOTE: Make sure the synchronizers are in the neutral position.

Install output shaft 1 assembly on the special tool.

Fig 6: Installing Output Shaft 1 Assembly On Special Tool
Courtesy of FORD MOTOR CO.
Install the special tool.

Fig 7: Installing Special Tool
Courtesy of FORD MOTOR CO.
Turn the gearset assembly over onto the special tool.

Fig 8: Turning Gear Set Assembly
Courtesy of FORD MOTOR CO.
Remove the special tool.

Fig 9: Removing Special Tool
Courtesy of FORD MOTOR CO.
Install the 4th/reverse gear shift fork.

Fig 10: Locating 4th/Reverse Gear Shift Fork
Courtesy of FORD MOTOR CO.
Install the 2nd/6th gear shift fork and linkage.

Fig 11: Locating 2nd/6th Gear Shift Fork And Linkage
Courtesy of FORD MOTOR CO.
NOTE: Make sure shift drum 1 is in the neutral position as shown in illustration.

Install shift drum 1.

Fig 12: Locating Shift Drum 1 Position
Courtesy of FORD MOTOR CO.
NOTE: Make sure shift drum 2 is in the neutral position as shown in illustration.

Install the 3rd gear linkage and shift drum 2.

Fig 13: Locating 3rd Gear Linkage And Shift Drum 2
Courtesy of FORD MOTOR CO.
Install the 1st/5th gear shift fork.

Fig 14: Locating 1st/5th Gear Shift Fork
Courtesy of FORD MOTOR CO.
Install the 3rd gear shift fork.

Fig 15: Locating 3rd Gear Shift Fork
Courtesy of FORD MOTOR CO.
Install the 4 shift fork rods.
1. Install the small shift fork rods.
2. Install the large shift fork rods.
  
  Fig 16: Identifying Small And Large Shift Fork Rods
  Courtesy of FORD MOTOR CO.
Install the oil spout.

Fig 17: Locating Oil Spout
Courtesy of FORD MOTOR CO.
NOTE: Make sure the output shaft bearing retainer brackets are positioned as shown in illustration.

Install the special tools on the output shafts assemblies.

Fig 18: Installing Special Tools On Output Shafts Assemblies
Courtesy of FORD MOTOR CO.
Install the transmission case onto the gearset assemblies.

Fig 19: Installing Transmission Case On Gear Set Assemblies
Courtesy of FORD MOTOR CO.
Install the 6 new output shaft bearing retainer bolts. Tighten in 2 stages.
- Stage 1: tighten to 10 Nm (89 lb-in).
- Stage 2: tighten to 32 Nm (24 lb-ft).
  
  Fig 20: Removing Output Shaft Bearing Retainer Bolts
  Courtesy of FORD MOTOR CO.
Install the special tool on the transmission case.

Fig 21: Installing Special Tool On Transmission Case
Courtesy of FORD MOTOR CO.
Turn the transmission case and gearset assembly over onto the special tool.
Remove the special tool.

Fig 22: Removing/Installing Special Tool
Courtesy of FORD MOTOR CO.
Install the magnet.

Fig 23: Locating Magnet
Courtesy of FORD MOTOR CO.
Install the small clock gears and clock gear pins.

Fig 24: Installing Small Clock Gears And Clock Gear Pins
Courtesy of FORD MOTOR CO.
Install the large clock gears and clock gear pins.

Fig 25: Installing Large Clock Gears And Clock Gear Pins
Courtesy of FORD MOTOR CO.
Install the park pawl and park pawl rod.

Fig 26: Installing Park Pawl And Rod
Courtesy of FORD MOTOR CO.
NOTE: Make sure the pin is installed as shown in illustration.

Install the park pawl actuation shaft assembly.

Fig 27: Locating Park Pawl Actuation Shaft Assembly And Pin
Courtesy of FORD MOTOR CO.
NOTE: If the differential bearings, differential, clutch housing and/or transmission case are replaced refer to DIFFERENTIAL SHIM SELECTION .

Install the differential.

Fig 28: Locating Differential
Courtesy of FORD MOTOR CO.
NOTE: Make sure the transmission case and the clutch housing are clean and no old sealant is present or transmission fluid leaks can occur and cause transmission damage.

NOTE: Make sure the park plunger and park plunger plug were removed from the the clutch housing or damage to the park pawl actuation shaft assembly (rooster comb) will occur.

Apply a 1 mm (0.039 in) bead of Gasket Maker around the inside of the bolt holes on the case side and completely around each dowel.

Fig 29: Identifying Gasket Maker Bead Applying Areas Around Bolt Holes And Dowel
Courtesy of FORD MOTOR CO.
Using the special tools, install the new clutch housing input shaft bearing.

Fig 30: Installing Clutch Housing Input Shaft Bearing Using Special Tools
Courtesy of FORD MOTOR CO.
Install the clutch housing input shaft bearing retainer and the new clutch housing input shaft bearing retainer bolts.
- Tighten to 11 Nm (97 lb-in).
  
  Fig 31: Locating Clutch Housing Input Shaft Bearing Retainer And Mounting Bolts
  Courtesy of FORD MOTOR CO.
NOTE: Do not overheat the bearing or damage to the bearing may occur.

Using a 1500W heat gun, or equivalent, heat the input shaft bearing in the clutch housing for approximately 5 minutes.

Fig 32: Heating Input Shaft Bearing In Clutch Housing Using Heat Gun
Courtesy of FORD MOTOR CO.
Install the clutch housing onto the transmission case.

Fig 33: Installing Clutch Housing On Transmission Case
Courtesy of FORD MOTOR CO.
Using the special tool and a hammer, tap the clutch housing down onto the transmission case.

Fig 34: Tapping Clutch Housing Into Transmission Case Using Special Tool And Hammer
Courtesy of FORD MOTOR CO.
Install the 18 bottom clutch housing-to-case bolts (13 shown in illustration).
- Tighten to 27 Nm (20 lb-ft).
  
  Fig 35: Locating Bottom Clutch Housing-To-Case Bolts
  Courtesy of FORD MOTOR CO.
Install the 3 top clutch housing-to-case bolts.
- Tighten to 27 Nm (20 lb-ft).
  
  Fig 36: Locating Top Clutch Housing-To-Case Bolts
  Courtesy of FORD MOTOR CO.
Install the park plunger.

Fig 37: Installing Park Plunger
Courtesy of FORD MOTOR CO.
Install the park plunger plug.
- Tighten to 43 Nm (32 lb-ft).
  
  Fig 38: Locating Park Plunger Plug
  Courtesy of FORD MOTOR CO.
Install the manual control lever and the new manual control lever bolt.
- Tighten to 26 Nm (19 lb-ft).
  
  Fig 39: Locating Manual Control Lever Bolt
  Courtesy of FORD MOTOR CO.
Install a new input shaft snap ring.

Fig 40: Locating Input Shaft Snap Ring
Courtesy of FORD MOTOR CO.
Using the special tools, install a new input shaft case seal.

Fig 41: Installing Input Shaft Case Seal Using Special Tools
Courtesy of FORD MOTOR CO.
Using the locating flange on the guide tube, install the guide tube.

Fig 42: Installing Guide Tube Using Locating Flange On Guide Tube
Courtesy of FORD MOTOR CO.
NOTE: The guide tube bolts must not project beyond the mounting surface of the clutch engagement levers.

Install the 3 guide tube bolts.
- Tighten to 8 Nm (71 lb-in).
  
  Fig 43: Locating Guide Tube Bolts
  Courtesy of FORD MOTOR CO.
Inspect the guide tube for wear or damage. Replace as necessary.

Fig 44: Locating Guide Tube
Courtesy of FORD MOTOR CO.
NOTE: One clutch actuator lever bushing shown in illustration, one per clutch actuator lever.

Install the clutch actuator lever bushings.

Fig 45: Locating Clutch Actuator Lever Bushings
Courtesy of FORD MOTOR CO.
NOTE: Be sure to properly handle the actuator lever as shown in illustration or damage may occur.

Install the clutch actuator lever 2.

Fig 46: Removing/Installing Clutch Actuator Lever
Courtesy of FORD MOTOR CO.
Install clutch motor 2 without the bolts to aide in the alignment of the clutch actuator lever.
Install the 2 clutch actuator lever 2 bolts.
- Tighten to 19 Nm (168 lb-in).
  
  Fig 47: Locating Clutch Actuator Lever Mounting Bolts
  Courtesy of FORD MOTOR CO.
NOTE: Be sure to properly handle the actuator lever as shown in illustration or damage may occur.

Install the clutch actuator lever 1.

Fig 48: Removing/Installing Clutch Actuator Lever
Courtesy of FORD MOTOR CO.
Install clutch motor 1 without the bolts to aide in the alignment of the clutch actuator lever.
Install the 2 clutch actuator lever 1 bolts.
- Tighten to 19 Nm (168 lb-in).
  
  Fig 49: Locating Clutch Actuator Lever Mounting Bolts
  Courtesy of FORD MOTOR CO.
NOTE: Tighten the spring retainer bolts by tightening them slightly in an alternating pattern or damage can occur to the clutch actuator levers.

NOTE: Make sure the spring retainer contour aligns with the actuator lever contour as shown in illustration.

NOTE: Make sure the serial number on the spring retainer matches the serial number on the actuator lever. If reusing the spring retainers and actuator levers use the marks made during removal for assembly.

Install the spring retainers and spring retainer bolts.
- Tighten to 26 Nm (19 lb-ft).
  
  Fig 50: Locating Serial Number On Spring Retainer And Actuator Lever
  Courtesy of FORD MOTOR CO.
Remove the clutch actuator lever locks if installed.

Fig 51: Locating Clutch Actuator Lever Locks
Courtesy of FORD MOTOR CO.
NOTE: Do not apply grease or other lubricants to the clutch actuator lever fingers, the engagement system bearing, or the Z-washers or clutch contamination can occur.

NOTE: The engagement system bearing unit should be installed easily.

Install the engagement system bearing unit.

Fig 52: Installing Engagement System Bearing Unit
Courtesy of FORD MOTOR CO.
NOTE: Do not tilt transmission after the Z-washers are installed, they may come off center and damage can occur.

Install the Z-washers onto the engagement system bearing unit and center them correctly.

Fig 53: Locating Engagement System Bearing Unit Z-Washers
Courtesy of FORD MOTOR CO.
If installing a new clutch go to step 70.
NOTE: Make sure the special tool washer is also installed.

Install the special tool in a vise.

Fig 54: Installing Special Tool Into Vise
Courtesy of FORD MOTOR CO.
Place the clutch on the special tool and align one clutch stud with the slotted hole on the special tool.

Fig 55: Aligning Clutch Stud With Slotted Hole On Special Tool
Courtesy of FORD MOTOR CO.
Install the special tool loosely on the clutch.

Fig 56: Installing Special Tool On Clutch
Courtesy of FORD MOTOR CO.
Install the special tool on the clutch making sure the legs are inserted in the slots.

Fig 57: Installing Special Tool On Clutch Properly
Courtesy of FORD MOTOR CO.
Turn the special tool clockwise to the stops and hold.

Fig 58: Turning Special Tool Clockwise
Courtesy of FORD MOTOR CO.
NOTE: Failure to rotate the self-adjuster to the stops before compressing the clutch, causes damage to the clutch.

Tighten the special tool until the 3 clutch 1 locks can be locked in place by hand.

Fig 59: Locking Clutch And Lock Using Special Tool
Courtesy of FORD MOTOR CO.
Install the special tool loosely on the clutch.

Fig 60: Installing Special Tool On Clutch
Courtesy of FORD MOTOR CO.
Using the special tool, move the clutch self-adjuster counterclockwise to the stop and hold.

Fig 61: Moving Clutch Self-Adjuster Counterclockwise Using Special Tool
Courtesy of FORD MOTOR CO.
NOTE: Make sure the clutch self-adjuster is held to the stops before compressing the clutch or damage will occur to the clutch.

NOTE: An audible click can be heard when the clutch locks lock.

While holding the clutch self-adjuster to the stops, use the special tool and compress the clutch to the stops on the clutch. The locks on clutch 2 lock at this time.

Fig 62: Compressing Clutch Using Special Tool
Courtesy of FORD MOTOR CO.
Remove the special tools.

Fig 63: Removing Special Tools
Courtesy of FORD MOTOR CO.
NOTE: The minimum number of engaged clutch locks is 6. Make sure the 6 locked clutch fingers align with the clutch studs as shown in illustration. If not, reset the clutch 2 locks as necessary.

Visually check the locks to make sure they have locked. 4 locks shown in illustration, 12 total.

Fig 64: Locating Aligning Position Of Locked Clutch Fingers And Clutch Studs
Courtesy of FORD MOTOR CO.
If installing a used clutch, verify the clutch is not worn or damaged. Perform the next 2 steps to check for clutch wear.
Check clutch 1 for wear by measuring the distance between the adjuster ring 1 long hole and lever 1 spring. Replace the clutch assembly if the measurement is 26 mm (1.023 in) or less.

Fig 65: Measuring Distance Between Adjuster Ring 1 Long Hole And Lever 1 Spring
Courtesy of FORD MOTOR CO.
Check clutch 2 for wear by measuring the distance between adjuster ring 2 and the cover. Replace the clutch assembly if the measurement is 15 mm (0.59 in) or less.

Fig 66: Measuring Distance Between Adjuster Ring 2 And Cover
Courtesy of FORD MOTOR CO.
Using the special tools, install the new inner input shaft seal.

Fig 67: Installing Inner Input Shaft Seal Using Special Tools
Courtesy of FORD MOTOR CO.
Apply a small amount of transmission fluid on the input shaft bearing surface.

Fig 68: Identifying Transmission Fluid Applying Areas On Input Shaft Bearing Surface
Courtesy of FORD MOTOR CO.
Apply a small amount of DPS6 Grease on both input shaft splines.

Fig 69: Identifying Grease Applying Areas On Input Shaft Splines
Courtesy of FORD MOTOR CO.
Verify the Z-washers are installed correctly.

Fig 70: Inspecting Z-Washers Installation Position
Courtesy of FORD MOTOR CO.
NOTE: Verify the clutch locks are locked prior to installation or the transmission may not operate correctly and damage can occur. If the clutch locks are not locked go to step 56 within this procedure.

NOTE: Make sure the angled lifting leg is installed in the location shown in illustration.

Using the special tools, install the clutch in the transmission.

Fig 71: Installing Clutch Into Transaxle Using Special Tools
Courtesy of FORD MOTOR CO.
Remove all the special tools.

Fig 72: Locating Special Tools Mounting Nuts
Courtesy of FORD MOTOR CO.
Install the special tools onto the transmission case.

Fig 73: Installing Special Tools Onto Transaxle Case
Courtesy of FORD MOTOR CO.
NOTE: Do not overtighten the special tool or damage can occur.

Using the special tools, push the clutch down with approximately 5 Nm (44 lb-in) of torque until seated on the input shaft bearing and the snap ring groove is visible.

Fig 74: Installing Special Tools Onto Transaxle Case
Courtesy of FORD MOTOR CO.
NOTE: Make sure the hollow input shaft snap ring is fully seated.

Install the new hollow input shaft snap ring.

Fig 75: Locating Hollow Input Shaft Snap Ring
Courtesy of FORD MOTOR CO.
NOTE: Align the index marks on the clutch hub and clutch.

Install the clutch hub.

Fig 76: Removing/Installing Clutch Hub
Courtesy of FORD MOTOR CO.
Install the new clutch hub snap ring in the position shown in illustration.

Fig 77: Installing Clutch Hub Snap Ring
Courtesy of FORD MOTOR CO.
NOTE: Do not turn the special tool more than 12 turns or damage to the clutch actuator engagement lever can occur.

Using the special tool, release the clutch 1 locks by slowly turning the special tool counterclockwise. An audible click will be heard when the clutch 1 lock is released. Repeat step to release clutch 2 locks.

Fig 78: Releasing Clutch 1 And 2 Locks Using Special Tool
Courtesy of FORD MOTOR CO.
Apply High Temperature Nickel Anti-Seize Lubricant to both clutch motor surfaces where indicated.

Fig 79: Identifying Lubricant Applying Areas On Clutch Motor Surfaces
Courtesy of FORD MOTOR CO.
Apply High Temperature Nickel Anti-Seize Lubricant to the clutch actuator lever splines as shown in illustration.

Fig 80: Identifying Lubricant Applying Areas On Clutch Actuator Lever Splines
Courtesy of FORD MOTOR CO.
Install the clutch motor 2 and the 4 clutch motor 2 bolts.
- Tighten to 5 Nm (44 lb-in).
  
  Fig 81: Locating Clutch Motor 2 And Mounting Bolts
  Courtesy of FORD MOTOR CO.
Install the clutch motor 1 and the 4 clutch motor 1 bolts.
- Tighten to 5 Nm (44 lb-in).
  
  Fig 82: Locating Clutch Motor 1 And Mounting Bolts
  Courtesy of FORD MOTOR CO.
NOTE: Be sure to use the 3.2 mm (0.125 in) input shaft speed sensor 2 shim or damage can occur to the transmission.

NOTE: Install a new O-ring if installing the existing input shaft speed sensor 2.

NOTE: Use a small amount of transmission fluid on the input shaft speed sensor 2 O-ring for installation.

Install the input shaft speed sensor 2.
1. Install the input shaft speed sensor 2 shim.
2. Install the input shaft speed sensor 2.
3. Install the input shaft speed sensor 2 bolt.
  - Tighten to 10 Nm (89 lb-in).
    
    Fig 83: Identifying Input Shaft Speed Sensor 2, Shim And Bolt
    Courtesy of FORD MOTOR CO.
NOTE: Be sure to use the 3.5 mm (0.137 in) input shaft speed sensor 1 shim on input shaft speed sensor 1 or damage can occur to the transmission.

NOTE: Install a new O-ring if installing the existing input shaft speed sensor 1.

NOTE: Use a small amount of transmission fluid on the input shaft speed sensor 1 O-ring for installation.

Install the input shaft speed sensor 1.
1. Install the input shaft speed sensor 1 shim.
2. Install the input shaft speed sensor 1.
3. Install the input shaft speed sensor 1 bolt.
  - Tighten to 10 Nm (89 lb-in).
    
    Fig 84: Identifying Input Shaft Speed Sensor 1, Shim And Bolt
    Courtesy of FORD MOTOR CO.
NOTE: If installing the old OSS sensor, install a new O-ring.

Install the OSS sensor and the OSS sensor bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 85: Locating Output Shaft Speed Sensor And Mounting Bolt
  Courtesy of FORD MOTOR CO.
Install the TR sensor and the 2 TR sensor bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 86: Locating Transmission Range Sensor And Mounting Bolts
  Courtesy of FORD MOTOR CO.
Carefully inspect the TCM and the transmission bore for debris or damage. Clean and/or repair as needed.
NOTE: Use a small amount of transmission fluid on the new O-rings prior to installation.

Install new O-rings if the TCM is being reused.

Fig 87: Identifying Transmission Fluid Applying Areas On O-Rings
Courtesy of FORD MOTOR CO.
NOTE: Do not force the TCM onto the transmission or damage may occur.

NOTE: Make sure the TCM sits flush on the transmission, or damage can occur.

Install the TCM. Apply light pressure to seat the O-rings. If the TCM does not push in place with light pressure, remove the TCM and slightly turn the TCM gears and retry installing the TCM.

Fig 88: Turning TCM Gears
Courtesy of FORD MOTOR CO.
Install the 4 TCM bolts.
- Tighten to 27 Nm (20 lb-ft).
  
  Fig 89: Locating TCM Mounting Bolts
  Courtesy of FORD MOTOR CO.
Install the wiring harness.

Fig 90: Locating Transmission Wiring Harness And Clips
Courtesy of FORD MOTOR CO.