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Assembling Transaxle

CAUTION: Whenever the transaxle has been disassembled, the bearing preload must be adjusted. The input shaft, output shaft and differential bearing preload can be adjusted by selecting shims to insert between the bearing races and the case on the case side.
  1. Using the special tool, install the input shaft seal.
    Fig 1: Installing Input Shaft Seal
    G02050038
  2. Install the input shaft bearing cup into the flywheel housing.
    Fig 2: Installing Input Shaft Bearing Cup Into Flywheel Housing
    G02050039
  3. Install the input shaft.
    Fig 3: Installing Input Shaft
    G02050040
  4. Position the bearing cup onto the bearing.
    Fig 4: Positioning Bearing Cup Onto Bearing
    G02050041
  5. Position the special tools.
    Fig 5: Positioning Special Tools
    G02050042
  6. Install the transaxle case.
    1. Position the transaxle case.
    2. Install the bolts.
    Fig 6: Installing Transaxle Case
    G02050043
  7. Mount a dial indicator to the transaxle case.
    Fig 7: Positioning Dial Indicator To Transaxle Case
    G02050044
  8. Rotate the input shaft to seat the bearings.
  9. Zero the dial indicator.
    Fig 8: Zeroing Dial Indicator
    G02050045
    10. CAUTION: The shaft must be lifted equally on both sides or it may cock to one side, resulting in an incorrect reading.
    Fig 9: Reading Input Shaft End Play
    G02050046
  10. Rotate the input shaft until the dial indicator returns to zero then raise the input shaft and read the end play.
  11. Repeat the previous step to obtain three readings within 0.10 mm (0.004 in) of each other. Use the formula below to select the correct shim size.
    Fig 10: Input Shaft Shim Size Formula
    G02050047
    12. CAUTION: Do not use more than two shims.
  12. From Shim Selection Kit meeting Ford specification, select the shim(s) that is closest to (or slightly thinner than) the final shim size determined in the previous step.
  13. Remove the transaxle case, special tools, bearing cup, and input shaft.
  14. Install the shim.
    Fig 11: Installing Input Shaft Shim
    G02050048
  15. Using the special tools, install the input shaft bearing cup.
    Fig 12: Installing Input Shaft Bearing Cup
    G02050049
  16. Install the funnel.
    Fig 13: Installing Funnel
    G02050050
  17. Using the special tools, install the output shaft bearing cup.
    Fig 14: Install Output Shaft Bearing Cup
    G02050051
  18. Install the output shaft.
    Fig 15: Installing Output Shaft
    G02050052
  19. Position the bearing cup onto the bearing.
    Fig 16: Positioning Bearing Cup Onto Bearing
    G02050053
    20. NOTE: The gauge halves must be turned to eliminate any gap between them.
    Fig 17: Position Special Tools
    G02050054
  20. Position the special tools.
  21. Install the transaxle case.
    1. Position the transaxle case.
    2. Install the bolts.
    Fig 18: Installing Transaxle Case
    G02050055
  22. Install a dial indicator on the transaxle case.
    Fig 19: Installing Dial Indicator To Transaxle Case
    G02050056
  23. Rotate the output shaft to seat the bearings.
  24. Zero the dial indicator.
    Fig 20: Zeroing Dial Indicator
    G02050057
    25. CAUTION: The shaft must be lifted equally on both sides or it may cock to one side, resulting in an incorrect reading.
    Fig 21: Reading Output Shaft End Play
    G02050058
  25. Rotate the output shaft until the dial indicator returns to zero then raise the output shaft and read the end play.
  26. Repeat the previous step to obtain three readings within 0.10 mm (0.004 in) of each other. Use the formula below to select the correct shim size.
    Fig 22: Output Shaft Shim Size Formula
    G02050059
    27. CAUTION: Do not use more than two shims.
  27. From Shim Selection Kit meeting Ford specification, select the shim(s) that is closest to (or slightly thinner than) the final shim size determined in the previous step.
  28. Remove the transaxle case, special tools, bearing cup and output shaft.
  29. Install the shim.
    Fig 23: Installing Output Shaft Shim
    G02050060
  30. Using the special tools, install the output shaft bearing cup.
    Fig 24: Installing Output Shaft Bearing Cup
    G02050061
  31. Using the special tools, install the differential bearing cup into the flywheel housing.
    Fig 25: Installing Differential Bearing Cup
    G02050062
  32. Install the differential.
    Fig 26: Installing Differential
    G02050063
  33. Position the bearing cup onto the bearing.
    Fig 27: Positioning Bearing Cup Onto Bearing
    G02050064
    34. NOTE: The gauge halves must be turned to eliminate any gap between them.
    Fig 28: Position Special Tools
    G02050065
  34. Position the special tools.
  35. Install the transaxle case.
    1. Position the transaxle case.
    2. Install the bolts.
    Fig 29: Installing Transaxle Case
    G02050066
  36. Using the special tool, adjust gauge until the free play is removed. Turn gauge back together.
    Fig 30: Adjusting Gauge Free Play
    G02050067
  37. Insert the special tool through the transaxle case and engage the differential pinion shaft.
    Fig 31: Inserting Special Tool
    G02050068
  38. Using the special tools, adjust gauge until the differential rotation is within specification.
    Fig 32: Adjusting Gauge Differential Rotation
    G02050069
  39. Measure the gap in the special tool.
    Fig 33: Measuring Special Tool Gap
    G02050070
  40. Add 0.15 mm (0.0059 in) to the measurement to achieve the final clearance.
    41. CAUTION: Do not use more than two differential shims.
    Fig 34: Differential Bearing Shims Identification Chart
    G02050071
  41. Use the following chart to select the differential bearing shims that are closest to (or slightly larger than) the value obtained in Step  40.
  42. Remove the transaxle case, special tools, bearing cup, and differential.
  43. Install the differential bearing cup shim(s) into the transaxle case.
    Fig 35: Installing Differential Bearing Cup Shim(s)
    G02050073
  44. Using the special tools, install the differential bearing cup into the transaxle case.
    45. Fig 36: Installing Differential Bearing Cup Into Transaxle Case
    G02050072
    NOTE: Transaxle case side shown, flywheel housing side similar.
    Fig 37: Install Halfshaft Seals
    G02050074
  45. Using the special tool, install the halfshaft seals.
  46. Install the reverse lever and shaft.
    1. Position the reverse lever.
    2. Install the reverse lever shaft.
    Fig 38: Install Reverse Lever And Shaft
    G02050075
  47. Install the reverse lever roll pin.
    Fig 39: Installing Reverse Lever Roll Pin
    G02050076
  48. Install the vent tube and the vent tube bolts.
    Fig 40: Installing Vent Tube And Vent Tube Bolts
    G02050077
  49. Using the special tool, install the shift control shaft seal.
    Fig 41: Installing Shift Control Shaft Seal
    G02050078
    50. NOTE: Install the boot with the drain hole facing downward when installed in the vehicle.
    Fig 42: Installing Shift Control Shaft Assembly
    G02050079
  50. Install the shift control shaft assembly.
  51. Install a new roll pin.
    Fig 43: Installing NEW Roll Pin
    G02050080
  52. Install the shift control shaft selector lever.
    1. Position the shift control shaft selector lever.
    2. Install the shift control shaft selector lever bolt.
    Fig 44: Installing Shift Control Shaft Selector Lever
    G02050081
  53. Install the shift control selector plate and spacer.
    1. Position the shift control selector plate and spacer.
    2. Install the bolts.
    Fig 45: Installing Shift Control Selector Plate And Spacer
    G02050082
  54. Install the differential.
    Fig 46: Installing Differential
    G02050083
  55. Install the output and input shafts as an assembly.
    Fig 47: Installing Output And Input Shafts Assembly
    G02050084
  56. Install the gear shifter fork and main shift control shaft assembly, spring and detent ball.
    Fig 48: Installing Gear Shifter Fork And Main Shift Control Shaft Assembly, Spring And Detent Ball
    G02050085
  57. Shift into second and fourth gears.
  58. Install the shift lever shaft and shift fork selector lever.
    1. Install the shift fork selector lever.
    2. Install the shift lever shaft.
    Fig 49: Installing Shift Lever Shaft And Shift Fork Selector Lever
    G02050086
  59. Install the shift lever shaft roll pin.
    Fig 50: Installing Shift Lever Shaft Roll Pin
    G02050087
  60. Install the shift control shaft and shift gate.
    1. Install the shift gate.
    2. Install the shift control shaft.
    Fig 51: Installing Shift Control Shaft And Shift Gate
    G02050088
  61. Install the shift gate bolt.
    Fig 52: Installing Shift Gate Bolt
    G02050089
  62. Install the reverse idler gear.
    1. Install reverse idler gear.
    2. Install reverse idler gear shaft.
    Fig 53: Installing Reverse Idler Gear
    G02050090
  63. Install the magnet.
    Fig 54: Installing Magnet
    G02050091
  64. Position the gear selector arm and reverse idler gear shaft.
    1. Align the end of the gear selector interlock sleeve with the gear selector arm.
    2. Face the reverse idler gear shaft hole in the direction shown.
    Fig 55: Positioning Gear Selector Arm And Reverse Idler Gear Shaft
    G02050092
    65. CAUTION: The transaxle case must be installed within four minutes after applying silicone gasket and sealant.
  65. Apply a small bead of silicone gasket and sealant to the transaxle mating surface.
  66. Install the transaxle case.
    1. Position the transaxle case.
    2. Install the 15 bolts.
    Fig 56: Installing Transaxle Case
    G02050093
  67. Install the lock bolt, spring, and ball.
    Fig 57: Installing Lock Bolt, Spring And Ball
    G02050094
    68. CAUTION: Make sure that the shift rail guide bolt is in the groove of the shift rail.
    Fig 58: Installing Reverse Idler Shaft Lock Bolt And Shift Rail Guide Bolt
    G02050095
  68. Install the reverse idler shaft lock bolt and shift rail guide bolt.
  69. Install the fifth speed gear and fifth gear spacer.
    1. Install fifth speed gear.
    2. Install the fifth gear spacer.
    Fig 59: Installing Fifth Speed Gear And Fifth Gear Spacer
    G02050096
  70. Install the fifth gear bushing.
    Fig 60: Installing Fifth Gear Bushing
    G02050097
  71. Measure the clearance between the fifth/reverse synchronizer sleeve and its shift fork.
    Fig 61: Measuring Clearance Between The Fifth/Reverse Synchronizer Sleeve And Shift Fork
    G02050098
  72. Install the fifth speed cluster gear.
    Fig 62: Installing Fifth Speed Cluster Gear
    G02050099
    73. CAUTION: The synchronizer blocking rings are not interchangeable. Make sure to keep them in the order that they were removed.
    Fig 63: Installing Synchronizer Blocking Ring
    G02050100
  73. Install the synchronizer blocking ring.
  74. Install the fifth/reverse shift fork and synchronizer hub assembly.
    Fig 64: Installing Fifth/Reverse Shift Fork And Synchronizer Hub Assembly
    G02050101
  75. Install a new reverse/fifth shift fork roll pin.
    Fig 65: Installing NEW Reverse/Fifth Shift Fork Roll Pin
    G02050102
    76. CAUTION: The synchronizer blocking rings are not interchangeable. Make sure to install them in the order that they were removed.
    Fig 66: Installing Reverse Synchronizer Blocking Ring
    G02050103
  76. Install the reverse synchronizer blocking ring.
  77. Install the reverse synchronizer blocking ring retainer assembly.
    1. Install the reverse synchronizer blocking ring retainer assembly.
    2. Install the spacer.
    Fig 67: Installing Reverse Synchronizer Blocking Ring Retainer Assembly
    G02050104
  78. Shift the transaxle into first gear.
    79. CAUTION: Do not reuse locknuts.
    CAUTION: Stake the locknuts.
    Fig 68: Installing Input And Output Shaft Locknuts
    G02050105
  79. Install the input and output shaft locknuts.
    1. Using the special tool, keep the input shaft from turning.
    2. Install new input and output shaft locknuts.
    80. CAUTION: The case cover must be installed within four minutes after applying silicone gasket and sealant.
  80. Apply a small bead of silicone gasket and sealant to the case and cover mating surface.
  81. Install the case cover.
    1. Position the case cover.
    2. Install the bolts.
    Fig 69: Installing Case Cover
    G02050106
  82. Install the clutch slave cylinder line bracket.
    1. Position the clutch slave cylinder line bracket.
    2. Install the bolts.
    Fig 70: Installing Clutch Slave Cylinder Line Bracket
    G02050107
  83. Install the reversing lamp switch.
    Fig 71: Installing Reversing Lamp Switch
    G02050108
  84. Rotate the transaxle 180 degrees.
  85. Install the park/neutral position (PNP) switch.
    Fig 72: Installing Park/Neutral Position (PNP) Switch
    G02050109
  86. Install the anchor bolt.
    Fig 73: Installing Anchor Bolt
    G02050110
  87. Install the clutch release fork and bearing.
    1. Install the clutch release fork and bearing.
    2. Install the boot.
    Fig 74: Installing Clutch Release Fork And Bearing
    G02050111
  88. Remove the transaxle from the special tool.
    Fig 75: Removing Transaxle From Special Tool
    G02050112
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