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Manual Transmission: Assembly: Transaxle: Assembly

  1. Apply lubricant throughout the assembly procedure. Lubricate all bearings, gears and synchronizers with the recommended transmission lubricant.
  2. Attach the transmission case to the Transmission Holding Fixture.
  3. Apply sealer to the reverse gear idler shaft plate mating face. Install the reverse gear idler shaft plate and the 3 reverse gear idler shaft plate bolts.
    • Tighten to 24 Nm (18 lb-ft).
  4. Install the reverse gear idler shaft.
    5. NOTE: If new output shaft bearings were installed, install new output shaft bearing cups. Always install new bearings and cups in sets.
    NOTE: Use a heat gun on the case bearing cup area to aid installation.
  5. Using the special tools, install the output shaft bearing cup in the case (transmission side).
    6. Fig 1: Installing Output Shaft Bearing Cup In Case
    GF0040180Courtesy of FORD MOTOR CO.
    NOTE: If new input shaft bearings were installed, install new input shaft bearing cups. Always install new bearings and cups in sets.
    NOTE: Use a heat gun on the case bearing cup area to aid installation.
  6. Using a suitable driver, install the input shaft bearing cup in the case (transmission side).
    7. Fig 2: Installing Input Shaft Bearing Cup In Case
    GF0040181Courtesy of FORD MOTOR CO.
    NOTE: If new differential bearings were installed, install new differential bearing cups. Always install new bearings and cups in sets.
    NOTE: Use a heat gun on the case bearing cup area to aid installation.
  7. Using a suitable driver, install the differential bearing cup in the case (transmission side).
    8. Fig 3: Installing Differential Bearing Cup In Case
    GF0040182Courtesy of FORD MOTOR CO.
    NOTE: If new input shaft bearings were installed, install new input shaft bearing cups. Always install new bearings and cups in sets.
    NOTE: Use a heat gun on the case bearing cup area to aid installation.
  8. Install a 1.00 mm (0.03 in) shim. Using a suitable driver, install the input shaft bearing cup in the case (clutch side).
    9. Fig 4: Installing Input Shaft Bearing Cup In Case
    GF0040183Courtesy of FORD MOTOR CO.
    NOTE: If new output shaft bearings were installed, install new output shaft bearing cups. Always install new bearings and cups in sets.
    NOTE: Use a heat gun on the case bearing cup area to aid installation.
  9. Install a 1.00 mm (0.03 in) shim. Using a suitable driver, install the output shaft bearing cup in the case (clutch side).
    10. Fig 5: Installing Output Shaft Bearing Cup In Case
    GF0040184Courtesy of FORD MOTOR CO.
    NOTE: If new differential bearings were installed, install new differential bearing cups. Always install new bearings and cups in sets.
    NOTE: Use a heat gun on the case bearing cup area to aid installation.
  10. Install a 1.10 mm (0.04 in) shim. Using a suitable driver, install the differential bearing cup in the case (clutch side).
    11. Fig 6: Installing Differential Bearing Cup In Case
    GF0040185Courtesy of FORD MOTOR CO.
  11. Engage the 4th gear synchronizer on the input shaft.
    12. Fig 7: Engaging 4th Gear Synchronizer On Input Shaft
    GF0040186Courtesy of FORD MOTOR CO.
  12. Assemble the input and output shafts together and put them in the transaxle case as an assembly.
    13. Fig 8: Assembling Input And Output Shafts
    G04517395Courtesy of FORD MOTOR CO.
  13. Install the differential assembly.
    14. Fig 9: Installing Differential Assembly
    GF0040188Courtesy of FORD MOTOR CO.
    NOTE: Do not apply sealer at this time.
  14. Position the housing and install the 16 transaxle housing bolts uniformly.
    • Tighten to 32 Nm (24 lb-ft).
    15. Fig 10: Locating Transaxle Housing Bolts
    GF0040189Courtesy of FORD MOTOR CO.
  15. Using the special tool, rotate the input shaft to seat the bearings.
    16. Fig 11: Rotating Input Shaft To Seat Bearings
    GF0040190Courtesy of FORD MOTOR CO.
  16. Install the special tool to measure input shaft end play. Make sure the dial indicator is off center on the end of the input shaft. Zero the dial indicator.
    17. Fig 12: Measuring Input Shaft End Play
    GF0040191Courtesy of FORD MOTOR CO.
  17. Measure the input shaft end play.
    1. Using a lever, lift up on the input shaft.
    2. Observe and record the dial indicator reading.
      • Carry out the measurement 3 times and calculate the average measurement. Example: 0.22 mm (0.008 in) + 0.23 mm (0.009 in) + 0.21 mm (0.008 in) divided by 3 = 0.008 in (0.203 mm).
    18. Fig 13: Measuring Input Shaft End Play
    GF0040192Courtesy of FORD MOTOR CO.
  18. Install the holding fixture to the transmission then install the dial indicator gauge to measure output shaft end play. Position the special tool on 4th gear. Zero the dial indicator.
    19. Fig 14: Measuring Output Shaft End Play
    GF0040193Courtesy of FORD MOTOR CO.
  19. Measure the output shaft end play.
    • Using a lever, lift up on the output shaft. Note the resulting measurement, for example, 0.32 mm.
    • Carry out the measurement 3 times and calculate the average measurement. Observe and record the dial indicator reading. Example: 0.32 mm (0.012 in) + 0.34 mm (0.013 in) + 0.33 mm (0.012 in) divided by 3 = 0.33 mm (0.012 in).
    20. Fig 15: Measuring Output Shaft End Play
    GF0040194Courtesy of FORD MOTOR CO.
  20. Install the special tools. Prepare the differential for measuring.
    • Rotate the output shaft and at the same time press downward. Set up the special tool and set it to zero. Carry out the measurement 3 times and calculate the average measurement.
    21. Fig 16: Zeroing Special Tool To Measure Differential End Play
    GF0040195Courtesy of FORD MOTOR CO.
  21. Using the special tools, measure the differential end play. Observe and record the dial indicator reading.
    22. Fig 17: Measuring Differential End Play
    GF0040196Courtesy of FORD MOTOR CO.
  22. Using the measurements, select the appropriate shims for the differential, input shaft and the output shaft. For additional information, refer to SPECIFICATIONS .
    23. NOTE: Use a heat gun on the case bearing cup area to aid removal.
  23. Remove the output shaft bearing cup, the input shaft bearing cup, the differential bearing cup and the shims (clutch side).
    24. NOTE: Use a heat gun on the case bearing cup area to aid installation.
  24. Install the appropriate shims and the bearing cups.
    1. Install the appropriate shims.
    2. Install the bearing cups.
    25. Fig 18: Identifying Bearing Cups And Shims
    GF0040197Courtesy of FORD MOTOR CO.
  25. Apply a light coat of petroleum jelly, then install the lower thrust washer. The tab on the washer faces downward.
    26. Fig 19: Locating Lower Thrust Washer
    GF0040198Courtesy of FORD MOTOR CO.
  26. Install the reverse idler gear and the upper thrust washer. Do not install the bearing at this time. Install the gear with the oil grooves facing downward.
    27. Fig 20: Locating Reverse Idler Gear With Oil Grooves Facing Down
    GF0040199Courtesy of FORD MOTOR CO.
    NOTE: Position the 4th gear selector ring into the neutral position.
  27. Push the reverse idler gear away from the output shaft bearing cup. Install the input shaft and the output shaft as an assembly. Position both shafts into the bearing cups and align with the reverse idler gear.
    28. Fig 21: Installing Input Shaft And Output Shaft
    GF0040200Courtesy of FORD MOTOR CO.
  28. Install the reverse idler gear needle bearing.
    29. Fig 22: Locating Reverse Idler Gear Needle Bearing
    GF0040201Courtesy of FORD MOTOR CO.
  29. Install the reverse idler gear retainer.
    30. Fig 23: Locating Reverse Idler Gear Retainer
    GF0040202Courtesy of FORD MOTOR CO.
  30. Install the shift forks.
    1. Install the 5th/reverse gear selector fork and position it to the side.
    2. Install the 3rd/4th gear selector fork.
    3. Install the 1st/2nd gear selector fork.
    31. Fig 24: Identifying Shift Forks
    GF0040203Courtesy of FORD MOTOR CO.
  31. Install the shift rails. When installed, the selector rods are the same height.
    32. Fig 25: Locating Selector Rods
    GF0040204Courtesy of FORD MOTOR CO.
  32. Install the differential assembly.
    33. Fig 26: Identifying Differential
    GF0040120Courtesy of FORD MOTOR CO.
  33. Install the magnetic disc.
    34. Fig 27: Locating Magnetic Disc
    GF0040121Courtesy of FORD MOTOR CO.
  34. Install the reverse idler gear retainer bolts.
    • Tighten to 34 Nm (24 lb-ft).
    35. Fig 28: Locating Reverse Idler Gear Retainer Bolts
    GF0040124Courtesy of FORD MOTOR CO.
  35. Clean the mating surfaces of the selector mechanism and the transaxle case. Apply a bead of sealant to the sealing surface of the transaxle case. Install the selector mechanism and the 6 selector mechanism bolts.
    • Tighten to 23 Nm (17 lb-ft).
    36. Fig 29: Locating Selector Mechanism
    GF0040205Courtesy of FORD MOTOR CO.
  36. Clean the mating surfaces of the transaxle main case. Apply a bead of sealant to the sealing surface on the transaxle case. Install the transaxle housing.
    37. Fig 30: Transaxle Housing
    GF0040119Courtesy of FORD MOTOR CO.
    NOTE: The transaxle housing must not be turned over to tighten the bolts.
    NOTE: Do not wait longer than 10 minutes to tighten the bolts due to the rapid cure time of the sealant.
  37. Install the 16 transaxle housing bolts.
    • Tighten to 32 Nm (24 lb-ft).
    38. Fig 31: Locating Transaxle Housing Bolts
    GF0040206Courtesy of FORD MOTOR CO.
  38. Install the vehicle speed sensor (VSS).
    • Tighten to 10 Nm (89 lb-in).
    39. Fig 32: Locating Vehicle Speed Sensor (VSS) Bolt
    GF0040207Courtesy of FORD MOTOR CO.
  39. Using the special tools, install new differential oil seals.
    40. Fig 33: Installing Differential Oil Seals
    GF0040208Courtesy of FORD MOTOR CO.
    CAUTION: If brake fluid is spilled on the paintwork, the affected area must be immediately washed down with cold water or damage to the surface can occur.
    CAUTION: Using suitable adhesive tape, cover the input shaft splines to prevent damage to the input shaft oil seal.
    NOTE: Do not apply grease on any area of the clutch slave cylinder.
  40. Install a new clutch slave cylinder with a new seal. Install the 3 clutch slave cylinder bolts.
    • Make sure the seal is correctly installed or it may cause starter failure.
    • Tighten bolts to 10 Nm (89 lb-in).
    41. Fig 34: Locating Clutch Slave Cylinder Bolts
    GF0040209Courtesy of FORD MOTOR CO.
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