LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Ford >> 2003 >> ZX2 Automatic >> Repair and Diagnosis >> External Pages >> Different car >> Section 456 (Automatic Transmission) >> Assembly >> Transaxle >> Assembly
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Section 456 (Automatic Transmission): Assembly: Transaxle: Assembly

WARNING: This page is about a different car, the 2002 Ford Focus. However, it is still accessible from the selected car via links, so may be relevant.
  1. Using the special tool, install the final drive input gear bearing.
    1. Install the final drive input gear bearing.
    2. Install the special tool.
      Fig 1: Installing Final Drive Input Gear Bearing
      G03433469Courtesy of FORD MOTOR CO.
  2. Using an arbor press and the special tools, seat the final drive input gear bearing.
    Fig 2: Seating Final Drive Input Gear Bearing
    G03433470Courtesy of FORD MOTOR CO.
  3. Install a new collapsible spacer.
    Fig 3: Installing Collapsible Spacer
    G03433471Courtesy of FORD MOTOR CO.
  4. Using the special tool, position the final drive input gear.
    Fig 4: Positioning Final Drive Input Gear
    G03433472Courtesy of FORD MOTOR CO.
    5. CAUTION: Hold the final drive input gear while installing the final drive input gear bearing to prevent it from falling out of the transaxle case.
  5. Rotate the transaxle 180 degrees.
  6. Using the special tools, install the final drive input gear bearing.
    Fig 5: Installing Final Drive Input Gear Bearing
    G03433473Courtesy of FORD MOTOR CO.
  7. Rotate the transaxle 180 degrees.
  8. Using the special tool, lock the final drive input gear.
    Fig 6: Locking Final Drive Input Gear
    G03433474Courtesy of FORD MOTOR CO.
  9. Rotate the transaxle 180 degrees.
    10. NOTE: A high tightening torque specification (between 400-450 N.m) is necessary to crush the collapsible spacer for correct bearing pre-load.
    NOTE: If the pre-load is too high a new collapsible spacer must be installed.
    Fig 7: Using Special Tools And Tightening Nut
    G03433475Courtesy of FORD MOTOR CO.
  10. Using the special tools, tighten the nut to achieve the preload specification.
  11. Rotate the transaxle 180 degrees.
    12. NOTE: Make sure that the final drive rotates.
    Fig 8: Unlocking Special Tool
    G03433476Courtesy of FORD MOTOR CO.
  12. Unlock the special tool.
  13. Rotate the transaxle 180 degrees.
    14. CAUTION: Make sure the bearing pre-load is within specification.
    NOTE: Rotate the gear 10 times to make sure that the bearings are correctly seated.
    Fig 9: Measuring Rotating Torque
    G03433477Courtesy of FORD MOTOR CO.
  14. Using the special tools, measure the rotating torque.
  15. After achieving the correct torque, remove the special tools and stake the nut to prevent movement.
    Fig 10: Removing Special Tools And Staking Nut To Prevent Movement
    G03433478Courtesy of FORD MOTOR CO.
  16. Rotate the transaxle 180 degrees.
  17. Position the transfer shaft gears in the transaxle case.
    Fig 11: Positioning Transfer Shaft Gears In Transaxle Case
    G03433479Courtesy of FORD MOTOR CO.
  18. Install the parking pawl return spring.
    Fig 12: Installing Parking Pawl Return Spring
    G03433480Courtesy of FORD MOTOR CO.
  19. Connect the spring.
    1. Install the parking pawl abutment.
    2. Install the lever.
    3. Install the pin.
    4. Connect the spring.
      Fig 13: Connecting Spring
      G03433481Courtesy of FORD MOTOR CO.
  20. Install the parking pawl assembly cover and bolts.
    Fig 14: Installing Parking Pawl Assembly Cover And Bolts
    G03433482Courtesy of FORD MOTOR CO.
  21. Install the differential case assembly.
    Fig 15: Installing Differential Case Assembly
    G03433483Courtesy of FORD MOTOR CO.
  22. Position the bearing cups.
    Fig 16: Positioning Bearing Cups
    G03433484Courtesy of FORD MOTOR CO.
  23. Install the special tools.
    Fig 17: Installing Special Tools
    G03433485Courtesy of FORD MOTOR CO.
    24. NOTE: The converter housing cover must be installed evenly or an incorrect reading will result.
  24. Using the special tools, assemble the transaxle for end play measurement.
    1. Position the converter housing.
    2. Install the long bolts and seat the case cover flat.
    3. Install the short bolts.
      Fig 18: Installing Converter Housing Bolts
      G03433486Courtesy of FORD MOTOR CO.
  25. Remove the converter housing.
    1. Remove bolts.
    2. Remove the converter housing.
      Fig 19: Removing Converter Housing
      G03433487Courtesy of FORD MOTOR CO.
  26. Remove the special tools.
    Fig 20: Removing Special Tools
    G03433488Courtesy of FORD MOTOR CO.
  27. Remove the bearing cups.
    Fig 21: Removing Bearing Cups
    G03433489Courtesy of FORD MOTOR CO.
    28. NOTE: If the plunger is above the contact surface, the reading will be incorrect.
    Fig 22: Measuring Depth Of Plunger On Special Tool (Transfer Shaft Shim)
    G03433490Courtesy of FORD MOTOR CO.
  28. To determine the correct transfer shaft shim, measure the depth of the plunger on the special tool and select the correct transfer shaft shim. For additional information, refer to SPECIFICATIONS .
    29. NOTE: If the plunger is above the contact surface, the reading will be incorrect.
    Fig 23: Measuring Depth Of Plunger On Special Tool (Differential Shaft Shim)
    G03433491Courtesy of FORD MOTOR CO.
  29. To determine the correct differential shaft shim, measure the depth of the plunger on the special tool and select the correct differential shaft shim. For additional information, refer to SPECIFICATIONS .
  30. Using the special tool, install the correct transfer shaft shim and bearing cup in to the converter housing.
    Fig 24: Installing Correct Transfer Shaft Shim And Bearing Cup In To Converter Housing
    G03433492Courtesy of FORD MOTOR CO.
  31. Using the special tool, install the correct differential shaft shim and differential case bearing cup in to the converter housing.
    Fig 25: Installing Correct Differential Shaft Shim And Differential Case Bearing Cup In To Converter Housing
    G03433493Courtesy of FORD MOTOR CO.
  32. Apply a 1 mm thick bead of Loctite 5699.
    Fig 26: Applying Thick Bead Of Loctite 5699
    G03433494Courtesy of FORD MOTOR CO.
  33. Position the converter housing on the transaxle case and install the bolts.
    Fig 27: Installing Bolts Of Converter Housing
    G03433495Courtesy of FORD MOTOR CO.
  34. Install the intermediate/overdrive band servo piston return spring.
    Fig 28: Installing Intermediate/Overdrive Band Servo Piston Return Spring
    G03433496Courtesy of FORD MOTOR CO.
  35. Install the intermediate/overdrive servo piston.
    Fig 29: Installing Intermediate/Overdrive Servo Piston
    G03433497Courtesy of FORD MOTOR CO.
  36. Install the O-ring seal.
    Fig 30: Installing O-Ring Seal
    G03433498Courtesy of FORD MOTOR CO.
    37. NOTE: The three bolts need to be loosely installed, then tightened in sequence to compress the intermediate/overdrive spring evenly.
    Fig 31: Installing Intermediate/Overdrive Band Servo Piston Cover
    G03433499Courtesy of FORD MOTOR CO.
  37. Install the intermediate/overdrive band servo piston cover.
  38. Install the shifter assembly and bolt.
    Fig 32: Installing Shifter Assembly And Bolt
    G03433500Courtesy of FORD MOTOR CO.
    39. NOTE: Lubricate the O-ring prior to assembly.
    Fig 33: Installing New O-Rings On Manual Lever Shaft
    G03433501Courtesy of FORD MOTOR CO.
  39. Install the new O-rings on the manual lever shaft.
  40. Install the manual lever shaft.
    Fig 34: Installing Manual Lever Shaft
    G03433502Courtesy of FORD MOTOR CO.
    41. NOTE: The roll pin does not need to sit flush with the shifter assembly.
    Fig 35: Installing New Manual Lever Shaft Roll Pin
    G03433503Courtesy of FORD MOTOR CO.
  41. Install a new manual lever shaft roll pin.
  42. Loosely install the transmission range (TR) sensor.
    Fig 36: Installing Transmission Range (TR) Sensor
    G03433504Courtesy of FORD MOTOR CO.
    43. NOTE: The neutral drive accumulator springs are thinner than the 1-2 accumulator springs.
    Fig 37: Installing Thinner And Longer Neutral Drive Accumulator Springs
    G03433505Courtesy of FORD MOTOR CO.
  43. Install the thinner and longer neutral drive accumulator springs.
  44. Install the neutral drive accumulator piston.
    Fig 38: Installing Neutral Drive Accumulator Piston
    G03433506Courtesy of FORD MOTOR CO.
  45. Install the 1-2 accumulator springs.
    Fig 39: Installing 1-2 Accumulator Springs
    G03433507Courtesy of FORD MOTOR CO.
  46. Install the 1-2 accumulator piston.
    Fig 40: Installing 1-2 Accumulator Piston
    G03433508Courtesy of FORD MOTOR CO.
  47. Inspect the seals. Lubricate and install the transaxle internal harness electrical connector.
    Fig 41: Installing Transaxle Internal Harness Electrical Connector
    G03433509Courtesy of FORD MOTOR CO.
    48. NOTE: Make sure that the manual valve is in the manual control valve shift lever.
    NOTE: Do not fully tighten the bolts at this stage.
    Fig 42: Installing Main Control Valve Body
    G03433510Courtesy of FORD MOTOR CO.
  48. Install the main control valve body.
  49. Tighten the main control valve body retaining bolts.
    • Tighten the bolts in the sequence shown.
      Fig 43: Identifying Tightening Torque Sequence Of Main Control Valve Body Retaining Bolts
      G03433511Courtesy of FORD MOTOR CO.
    50. NOTE: It is necessary to connect the connectors in the same positions as noted in disassembly. Connector color letters are cast in the solenoid body.
  50. Install the main control wiring harness, connect the electrical connectors and install the ground wire bolt.
    1. Solenoid SSC; Color N (Neutral/White).
    2. Solenoid SSE; Color G (Green).
    3. Solenoid SSD; Color L (Blue).
    4. Solenoid EPC; Color B (Black).
    5. Solenoid SSA; Color N (Neutral).
    6. Solenoid SSB; Color B (Black).
      Fig 44: Installing Main Control Wiring Harness
      G03433512Courtesy of FORD MOTOR CO.
  51. Install the fluid filter.
    Fig 45: Installing Fluid Filter
    G03433513Courtesy of FORD MOTOR CO.
  52. Connect the transmission fluid temperature (TFT) sensor.
    Fig 46: Connecting Transmission Fluid Temperature (TFT) Sensor
    G03433514Courtesy of FORD MOTOR CO.
  53. Apply a 1.5 mm thick bead of Loctite 5699 to the transaxle fluid pan.
    Fig 47: Applying Bead Of Loctite 5699 To Transaxle Fluid Pan
    G03433515Courtesy of FORD MOTOR CO.
  54. Install the transaxle fluid pan.
    Fig 48: Installing Transaxle Fluid Pan
    G03433516Courtesy of FORD MOTOR CO.
  55. Rotate the transaxle 180 degrees.
  56. Install the low/reverse clutch piston.
    Fig 49: Installing Low/Reverse Clutch Piston
    G03433517Courtesy of FORD MOTOR CO.
  57. Install the low/reverse clutch return spring.
    Fig 50: Installing Low/Reverse Clutch Return Spring
    G03433518Courtesy of FORD MOTOR CO.
  58. Install the bevel ring with the outer edge uppermost.
    Fig 51: Installing Bevel Ring With Outer Edge Uppermost
    G03433519Courtesy of FORD MOTOR CO.
  59. Inspect the position of the bevel ring.
    1. Make sure the low/reverse clutch piston is seated.
    2. Make sure the bevel ring is installed with the inside edge facing down.
      Fig 52: Inspecting Position Of Bevel Ring
      G03433520Courtesy of FORD MOTOR CO.
  60. Install the low one-way clutch inner race.
    Fig 53: Installing Low One-Way Clutch Inner Race
    G03433521Courtesy of FORD MOTOR CO.
    61. NOTE: The opening of the retaining ring must be at the ten o'clock position.
    Fig 54: Installing Low One-Way Clutch Retaining Ring
    G03433522Courtesy of FORD MOTOR CO.
  61. Install the low one-way clutch retaining ring.
  62. Install the low/reverse plates and pressure plate.
    Fig 55: Installing Low/Reverse Plates And Pressure Plate
    G03433523Courtesy of FORD MOTOR CO.
  63. Install the low reverse clutch plate selective retaining ring.
    • Check the clutch clearance. For additional information, refer to SPECIFICATIONS .
      Fig 56: Installing Low Reverse Clutch Plate Selective Retaining Ring
      G03433524Courtesy of FORD MOTOR CO.
    64. NOTE: Make sure that the snap ring is installed before installing the planet assembly.
    Fig 57: Installing Planet Assembly
    G03433525Courtesy of FORD MOTOR CO.
  64. Install the planet assembly.
    65. CAUTION: The edge of the planet assembly must fit flush with the transaxle case.
    Fig 58: Inspecting Planet Assembly For Installation
    G03433526Courtesy of FORD MOTOR CO.
  65. Inspect the planet assembly installation.
    66. CAUTION: The planet assembly must only rotate counterclockwise.
  66. Check to make sure that the one way clutch is correctly installed.
    • Rotate the planet assembly clockwise and counterclockwise.
      Fig 59: Rotating Planet Assembly Clockwise And Counterclockwise
      G03433527Courtesy of FORD MOTOR CO.
  67. Install the intermediate/overdrive drum assembly.
    Fig 60: Installing Intermediate/Overdrive Drum Assembly
    G03433528Courtesy of FORD MOTOR CO.
  68. Install the intermediate/overdrive band.
    Fig 61: Installing Intermediate/Overdrive Band
    G03433529Courtesy of FORD MOTOR CO.
  69. Install the direct clutch cylinder thrust bearing with the rollers facing up.
    Fig 62: Installing Direct Clutch Cylinder Thrust Bearing With Rollers Facing Up
    G03433530Courtesy of FORD MOTOR CO.
  70. Install new end cover to case seals.
    Fig 63: Installing New End Cover To Case Seals
    G03433531Courtesy of FORD MOTOR CO.
  71. Install new end cover seals.
    Fig 64: Installing New End Cover Seals
    G03433532Courtesy of FORD MOTOR CO.
  72. Install the direct clutch hub bearing shim and an additional shim to increase the total shim thickness to the specification shown or greater.
    Fig 65: Installing Direct Clutch Hub Bearing Shim
    G03433533Courtesy of FORD MOTOR CO.
  73. Measure the gap between the transaxle end cover and the transaxle assembly.
    1. Position the transaxle end cover on the transaxle assembly.
    2. Measure the gap between the transaxle end cover and the transaxle assembly.
      Fig 66: Measuring Gap Between Transaxle End Cover And Transaxle Assembly
      G03433534Courtesy of FORD MOTOR CO.
  74. Remove the transaxle end cover.
    Fig 67: Removing Transaxle End Cover
    G03433535Courtesy of FORD MOTOR CO.
    75. NOTE: The clearance for the direct clutch shim is 0.05 - 0.50 mm (0.002 - 0.020 in).
    NOTE: The correct shim thickness is between the minimum and maximum value.
  75. Select and install the correct direct clutch hub bearing shim:
    • Line 1: total amount of shim thickness used during transaxle end cover mock up.
    • Line 2: measure the gap between transaxle end cover and transaxle case.
    • Line 3: subtract Line 2 from Line 1 to obtain the actual clearance.
    • Line 4: subtract 0.05 mm (0.002 in) from Line 3 for maximum shim thickness.
    • Subtract 0.50 mm (0.020 in) from Line 3 for the minimum shim thickness.
      Fig 68: Installing Correct Direct Clutch Hub Bearing Shim
      G03433536Courtesy of FORD MOTOR CO.
    76. CAUTION: Make sure that the sealant does not enter the fluid return holes.
    Fig 69: Applying Bead Of Loctite 5699 To Transaxle End Cover
    G03433537Courtesy of FORD MOTOR CO.
  76. Apply a 1 mm thick bead of Loctite 5699 to the transaxle end cover.
  77. Install the transaxle end cover.
    Fig 70: Installing Transaxle End Cover
    G03433538Courtesy of FORD MOTOR CO.
  78. Using the special tool, collapse the intermediate/overdrive band to specification then back out three and a half turns.
    Fig 71: Installing Intermediate/Overdrive Band
    G03433539Courtesy of FORD MOTOR CO.
  79. Holding the special tool, lightly seat the nut against the transaxle case, then remove the special tool without changing the relationship of the nut on the bolt.
    Fig 72: Removing Special Tool
    G03433540Courtesy of FORD MOTOR CO.
  80. Using the special tool, select an intermediate/overdrive band bolt that measures from the end of the bolt to the face of the nut as shown.
    Fig 73: Identifying Intermediate/Overdrive Band Bolt Measuring From End Of Bolt To Face Of Nut
    G03433541Courtesy of FORD MOTOR CO.
    81. NOTE: Apply thread sealer to the bolt.
    Fig 74: Installing Intermediate/Overdrive Band Anchor Bolt
    G03433542Courtesy of FORD MOTOR CO.
  81. Install the intermediate/overdrive band anchor bolt.
  82. Rotate the transaxle 180 degrees.
  83. Install the forward clutch hub.
    Fig 75: Installing Forward Clutch Hub
    G03433543Courtesy of FORD MOTOR CO.
  84. Install the forward clutch assembly.
    Fig 76: Installing Forward Clutch Assembly
    G03433544Courtesy of FORD MOTOR CO.
  85. Install the forward clutch thrust washer.
    Fig 77: Installing Forward Clutch Thrust Washer
    G03433545Courtesy of FORD MOTOR CO.
  86. Lubricate and install new fluid pump seals.
    Fig 78: Installing New Fluid Pump Seals
    G03433546Courtesy of FORD MOTOR CO.
  87. Install the fluid pump (do not force the pump down at this time).
    Fig 79: Installing Fluid Pump
    G03433547Courtesy of FORD MOTOR CO.
  88. Install the fluid pump bolts.
    • Use the bolts to seat the fluid pump.
    • Tighten bolts in an alternating sequence.
      Fig 80: Installing Fluid Pump Bolts
      G03433548Courtesy of FORD MOTOR CO.
  89. Install the output shaft speed (OSS) sensor.
    Fig 81: Installing Output Shaft Speed (OSS) Sensor
    G03433549Courtesy of FORD MOTOR CO.
    90. NOTE: Apply thread sealer to the bolt.
    Fig 82: Installing Turbine Shaft Speed (TSS) Sensor
    G03433550Courtesy of FORD MOTOR CO.
  90. Install the turbine shaft speed (TSS) sensor.
  91. Using the special tool, align the TR sensor and tighten the bolts.
    Fig 83: Identifying TR Sensor Bolts Tightening Torque
    G03433551Courtesy of FORD MOTOR CO.
    92. CAUTION: Do not use air tools on this bolt. Hold the manual control lever while tightening the manual control lever bolt.
    Fig 84: Installing Manual Control Lever
    G03433552Courtesy of FORD MOTOR CO.
  92. Install the manual control lever.
  93. Install the torque converter.
    Fig 85: Installing Torque Converter
    G03433553Courtesy of FORD MOTOR CO.
  94. Using the special tool, secure the torque converter.
    Fig 86: Installing Special Tool On Torque Converter
    G03433554Courtesy of FORD MOTOR CO.
scientia non olet · About LEMON Manuals