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Manual Transaxle/Transmission: Assembly: Transaxle: Assembly

    CAUTION: Bearing races require a heating and cooling procedure and special tools for installation. This procedure must be followed to provide accurate preload measurements.
  1. Clean and check all parts carefully before assembly.
    • All sliding parts should be lubricated with Mercon® Multi-Purpose Automatic Transmission Fluid XT-2-QDX meeting Mercon® specification plus 2% Friction Modifier C8AZ-19B546-A meeting Ford specification EST-M2C118-A.
    2. NOTE: Heat the transaxle housing to approximately 80°C.
  2. Install the reverse gear idler shaft.
    1. Apply Gasket Maker F8AZ -19B508-AB meeting Ford specification WSK-M2G348-A5 to the reverse gear idler shaft plate mating face.
    2. Align the reverse gear idler shaft plate using the longer locating bolt and drive it in.
    3. Remove the locating bolt and install the original bolts.
      Fig 1: Installing Reverse Gear Idler Shaft
      G03419747Courtesy of FORD MOTOR CO.
    3. CAUTION: The press pressure must not exceed 15 kN.
  3. Install the bearing cups on the transaxle housing side.
    • Heat the housing area to approximately 80°C.
    • Cool down the bearing cups and install them.
    • Install the bearing cups of the:
    • Input shaft using special tools (205-153, 303-420 and 205-267).
    • Output shaft using special tool (205-153).
    • Differential using special tools (205-153 and 308-121).
      Fig 2: Installing Bearing Cups On Transaxle Housing Side
      G03419748Courtesy of FORD MOTOR CO.
    4. CAUTION: Press the bearing races down again. The press pressure must not exceed 15 kN.
  4. Measuring shim to be installed:
    • Input shaft: 1.00 mm
    • Output shaft: 1.00 mm
    • Differential: 1.10 mm
    5. CAUTION: The press pressure must not exceed 15 kN.
  5. Install the measuring shims and the bearing cups in the housing section at the clutch end.
    • Heat the housing area to approximately 80°C.
    • Cool down the bearing cups.
    1. Install the measuring shims.
    2. Install the bearing cups.
      • Install the bearing cups of the:
      • Input shaft using special tools (205-153 and 308-221).
      • Output shaft using special tool (205-153).
      • Differential using special tools (205-153 and 308-121).
        Fig 3: Installing Measuring Shims And Bearing Cups
        G03419749Courtesy of FORD MOTOR CO.
    6. CAUTION: Do not use the bearing as a support. Support the differential under the gear.
    Fig 4: Installing Bearing
    G03419750Courtesy of FORD MOTOR CO.
  6. Using the special tools, install the bearing.
    7. NOTE: Do not oil taper roller bearings which are to be used again. New taper roller bearings can be installed without any treatment.
    Fig 5: Installing Fourth Gear Synchronizer On Input Shaft
    G03419751Courtesy of FORD MOTOR CO.
  7. Install the fourth gear synchronizer on the input shaft.
  8. Assemble the input and output shafts together and insert them in the transaxle case as an assembly.
    Fig 6: Assembling Input And Output Shafts
    G03419752Courtesy of FORD MOTOR CO.
    9. NOTE: Do not oil taper roller bearings which are to be used again. New taper roller bearings can be installed without any treatment.
    Fig 7: Installing Differential Assembly
    G03419753Courtesy of FORD MOTOR CO.
  9. Install the differential assembly.
  10. Position the housing and tighten the sixteen transaxle housing bolts uniformly.
    Fig 8: Installing Transaxle Housing Bolts
    G03419754Courtesy of FORD MOTOR CO.
  11. Prepare the input shaft for measuring.
    • Using the special tool, turn the input shaft back and forth to settle the bearings.
      Fig 9: Turning Input Shaft
      G03419755Courtesy of FORD MOTOR CO.
  12. Install the special tool on the transaxle housing and set the indicator to zero.
    Fig 10: Installing Special Tool On Transaxle Housing
    G03419756Courtesy of FORD MOTOR CO.
    13. NOTE: Carry out steps, and three times and calculate the average measurement.
  13. Using the special tool, measure the input shaft end float.
    1. Lift the input shaft with a lever.
    2. Note the resulting measurement.
      • Example: 0.22 mm + 0.23 mm + 0.21 mm divided by three = 0.22 mm.
        Fig 11: Measuring Input Shaft End Float
        G03419757Courtesy of FORD MOTOR CO.
  14. Install the special tool.
    • Turn the output shaft back and forth 20 times to settle the bearings (by means of the input shaft - see step).
    1. Install the special tool.
    2. Install the bolts.
    3. Position the special tool on the fourth gear wheel.
      Fig 12: Installing Special Tool
      G03419758Courtesy of FORD MOTOR CO.
    15. NOTE: Carry out steps and three times and calculate the average measurement.
  15. Using the special tool, measure the output shaft end float.
    • Lift the output shaft with a lever and note the resulting measurement, e.g. 0.32 mm.
    • Example: 0.32 m + 0.34 mm + 0.33 mm divided by three = 0.33 mm.
      Fig 13: Measuring Output Shaft End Float
      G03419759Courtesy of FORD MOTOR CO.
  16. Using the special tools, prepare the differential for measuring.
    • Using the special tool 308-224, turn the output shaft back and forth and at the same time press down.
    • Install the special tool 100-002 and set to zero.
      Fig 14: Installing Special Tool
      G03419760Courtesy of FORD MOTOR CO.
    17. NOTE: Carry out steps and three times and calculate the average measurement.
  17. Measure the differential end float.
    • Using the special tool lift the differential and note the resulting measurement.
      Fig 15: Measuring Differential End Float
      G03419761Courtesy of FORD MOTOR CO.
  18. Select the correct shim(s) for the differential, input and output shafts. Refer to the SHIM SELECTION SPECIFICATIONS .
  19. Using the special tools, remove the bearing outer races and shim of the differential, the input shaft and the output shaft again.
    • Install the special tool in the housing recesses.
      Fig 16: Removing Bearing Outer Races And Differential Shim
      G03419762Courtesy of FORD MOTOR CO.
    20. CAUTION: The press pressure must not exceed 15 kN.
  20. Install the selected shims and the bearing cups in the housing section at the clutch end.
    • Heat the housing area to approximately 80°C.
    • Cool down the bearing cups.
    1. Install the selected shims.
    2. Install the bearing cups of the:
      • Input shaft using special tools (250-153 and 308-221).
      • Output shaft using special tool (250-153).
      • Differential using special tools (250-153 and 308-121)
        Fig 17: Installing Shims And Bearing Cups In Housing Section
        G03419763Courtesy of FORD MOTOR CO.
    21. CAUTION: Press the bearing races down again. The press pressure must not exceed 15 kN.
  21. Installation hook for reverse gear idler (to be fabricated by technician).
    • Diameter of the wire: 3 mm.
      Fig 18: Installing Reverse Gear Idler Hook
      G03419764Courtesy of FORD MOTOR CO.
  22. Install the reverse gear idler.
    1. Lower thrust washer
    2. Needle roller bearing
    3. Install the installation hook.
    4. Reverse gear idler (the small collar facing downwards)
    5. Upper thrust washer
    6. Reverse gear idler shaft mounting
      Fig 19: Installing Reverse Gear Idler
      G03419765Courtesy of FORD MOTOR CO.
  23. Install the input and output shafts.
    • Lubricate the taper roller bearings with Mercon® Multi-Purpose Automatic Transmission Fluid XT-2-QDX meeting Mercon® specification plus 2% Friction Modifier C8AZ-19B546-A meeting Ford specification EST-M2C118-A.
    1. Install the input and output shafts together.
    2. Remove the installation hook.
    3. Press the reverse gear idler shaft mounting down.
    4. Apply Gasket Maker to the threads of the bolts and tighten them.
      Fig 20: Installing Input And Output Shafts
      G03419766Courtesy of FORD MOTOR CO.
    24. NOTE: Make sure the fourth gear selector ring is in the neutral position.
    Fig 21: Installing Fifth/Reverse Gear Selector Fork
    G03419767Courtesy of FORD MOTOR CO.
  24. Install the fifth/reverse gear selector fork and position it to one side.
  25. Install the third/fourth gear selector fork.
    Fig 22: Installing Third/Fourth Gear Selector Fork
    G03419768Courtesy of FORD MOTOR CO.
    26. NOTE: When installed correctly, the selector rods are the same height.
    Fig 23: Installing First/Second Gear Selector Fork And Rods
    G03419769Courtesy of FORD MOTOR CO.
  26. Install the first/second gear selector fork and rods.
  27. Install the differential assembly.
    1. Differential assembly.
    2. Magnetic disk in the recess.
      Fig 24: Installing Differential Assembly
      G03419770Courtesy of FORD MOTOR CO.
  28. Treat the mating face with Gasket Maker.
    1. The mating face must be dry. Gasket Maker F8AZ -19B508-AB meeting Ford specification WSK-M2G348-A5 must be applied in an even coating to the inside of the mating face. (The even bead of Gasket Maker should have a diameter of 2 mm).
      Fig 25: Identifying Mating Face
      G03419771Courtesy of FORD MOTOR CO.
    29. NOTE: The transaxle housing must not be turned over to tighten the bolts.
  29. Install the transaxle housing (clutch end).
    • Tighten the 16 bolts within 15 minutes, working diagonally.
      Fig 26: Installing Transaxle Housing (Clutch End)
      G03419772Courtesy of FORD MOTOR CO.
    30. NOTE: Make sure the transaxle is in neutral (the gearshift lever and selector lever must be vertical).
  30. Position the selector mechanism and install the bolts.
    • Coat the mating face with Gasket Maker F8AZ -19B508-AB meeting Ford specification WSK-M2G348-A5.
      Fig 27: Positioning Selector Mechanism And Installing Bolts
      G03419773Courtesy of FORD MOTOR CO.
  31. Using the special tool and the preload gauge, measure the turning torque.
    • Engage fourth gear.
    • Measure the turning torque.
    • If the turning torque is too high, all the measurements (to establish the required shim thickness) must be repeated.
      Fig 28: Measuring Turning Torque
      G03419774Courtesy of FORD MOTOR CO.
  32. Install the vehicle speed sensor (VSS).
    1. Install the vehicle speed driven gear (2.5L engine). Install the trigger wheel and VSS (2.0L engine).
    2. Install the roll pin.
      Fig 29: Installing Vehicle Speed Sensor
      G03419775Courtesy of FORD MOTOR CO.
  33. Using the special tools, install the differential oil seals.
    Fig 30: Installing Differential Oil Seals
    G03419776Courtesy of FORD MOTOR CO.
  34. Install the clutch slave cylinder.
    • Using a new oil seal and Gasket Maker F8AZ -19B508-AB meeting Ford specification WSK-M2G348-A5, install the clutch slave cylinder
      Fig 31: Installing Clutch Slave Cylinder
      G03419777Courtesy of FORD MOTOR CO.
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