Manual Transaxle: Disassembly: Transaxle

Special Tool(s) 

Fig 1: Identifying Special Tools (1 Of 2)

Courtesy of FORD MOTOR CO.

Fig 2: Identifying Special Tools (2 Of 2)

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Fig 3: Exploded View Of Transaxle/Transmission (1 Of 2)

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Fig 4: Exploded View Of Transaxle/Transmission (2 Of 2)

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1. Clean the transaxle exterior with solvent before disassembly.
2. Clean all removed parts (except sealed bearings) and all sealing surfaces with solvent, and dry with compressed air.
WARNING: Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes. Wear protective eye wear whenever using compressed air. Failure to follow these instructions may result in personal injury.
3. Clean out all holes and passages with compressed air and verify that there are no obstructions.
4. Using the special tool, mount the transaxle to a bench.
   Fig 5: Mounting Transaxle To Bench Using Special Tool

   Courtesy of FORD MOTOR CO.
5. Remove the clutch release fork and bearing.
   1. Remove the boot.
   2. Remove the clutch release fork and bearing.
      Fig 6: Removing Clutch Release Fork And Bearing

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6. Remove the anchor bolt.
   Fig 7: Removing Anchor Bolt

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7. Remove the park/neutral position (PNP) switch.
   Fig 8: Removing Park/Neutral Position (PNP) Switch

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8. Remove the bolt and the vehicle speed sensor (VSS).
   Fig 9: Removing Bolt And Vehicle Speed Sensor

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9. Rotate the transaxle 180 degrees.
10. Remove the reversing lamp switch.
    Fig 10: Removing Reversing Lamp Switch

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11. Remove the clutch slave cylinder line bracket.
    1. Remove the bolts.
    2. Remove the clutch slave cylinder line bracket.
       Fig 11: Removing Clutch Slave Cylinder Line Bracket

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12. Shift the transaxle into first gear.
13. Remove the case cover.
    1. Remove the bolts.
    2. Remove the case cover.
       Fig 12: Removing Case Cover

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CAUTION: Do not reuse locknuts.
14. Remove the input and output shaft locknuts and discard.
    1. Using the special tool, keep the input shaft from turning.
    2. Remove the input and output shaft locknuts and discard.
       Fig 13: Removing Input And Output Shaft Locknuts

       Courtesy of FORD MOTOR CO.
CAUTION: The synchronizer blocking rings are not interchangeable. Make sure to keep them in the order that they were removed.
Fig 14: Removing Reverse Synchronizer Blocking Ring
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15. Remove the reverse synchronizer blocking ring.
16. Remove and discard the reverse/fifth shift fork roll pin.
    Fig 15: Removing And Discarding The Reverse/Fifth Shift Fork Roll Pin

    Courtesy of FORD MOTOR CO.
17. Remove the reverse/fifth shift fork and synchronizer hub assembly.
    Fig 16: Removing Reverse/Fifth Shift Fork And Synchronizer Hub Assembly

    Courtesy of FORD MOTOR CO.
18. Remove the synchronizer blocking ring.
    Fig 17: Removing Synchronizer Blocking Ring

    Courtesy of FORD MOTOR CO.
19. Remove the fifth speed cluster gear.
    Fig 18: Removing Fifth Speed Cluster Gear

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20. Remove the fifth gear bushing.
    Fig 19: Removing Fifth Gear Bushing

    Courtesy of FORD MOTOR CO.
21. Remove the fifth speed gear.
    Fig 20: Removing Fifth Speed Gear

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22. Remove the reverse idler shaft lock bolt and shift rail guide bolt.
    Fig 21: Removing Reverse Idler Shaft Lock Bolt And Shift Rail Guide Bolt

    Courtesy of FORD MOTOR CO.
23. Remove the bolt, spring, and ball.
    Fig 22: Removing Bolt, Spring, And Ball

    Courtesy of FORD MOTOR CO.
24. Separate the transaxle case.
    1. Remove the 15 transaxle case bolts.
    2. Separate the transaxle case.
       Fig 23: Separating Transaxle Case

       Courtesy of FORD MOTOR CO.
25. Remove the magnet.
    Fig 24: Remove the magnet

    Courtesy of FORD MOTOR CO.
26. Remove the reverse idler gear.
    1. Remove the reverse idler gear shaft.
    2. Remove the reverse idler gear.
       Fig 25: Removing Reverse Idler Gear Shaft

       Courtesy of FORD MOTOR CO.
27. Remove the shift gate bolt.
    Fig 26: Removing Shift Gate Bolt

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28. Remove the shift control shaft and shift gate.
    1. Remove the shift control shaft.
    2. Remove the shift gate.
       Fig 27: Removing Shift Gate

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29. Remove the shift lever shaft roll pin.
    Fig 28: Removing Shift Lever Shaft Roll Pin

    Courtesy of FORD MOTOR CO.
30. Remove the shift lever shaft and shift fork selector lever.
    1. Remove the shift lever shaft.
    2. Remove the shift fork selector lever.
       Fig 29: Removing Shift Lever Shaft

       Courtesy of FORD MOTOR CO.
31. Shift into second and fourth gears.
WARNING: When removing the gear shifter fork and main shift control shaft assembly the detent ball will fly out. Hold a shop towel over the detent ball and spring to prevent the ball from becoming airborne. Failure to follow these instructions may result in personal injury.
Fig 30: Removing Gear Shifter Fork And Main Shift Control Shaft Assembly, Detent
Courtesy of FORD MOTOR CO.
32. Remove the gear shifter fork and main shift control shaft assembly, detent ball and spring.
33. Remove the output and input shafts as an assembly.
    Fig 31: Removing Output And Input Shafts As An Assembly

    Courtesy of FORD MOTOR CO.
34. Remove the differential.
    Fig 32: Removing Differential

    Courtesy of FORD MOTOR CO.
NOTE: Flywheel housing side shown, transaxle case side similar.
Fig 33: Removing Input Shaft Bearing Cups
Courtesy of FORD MOTOR CO.
35. Remove the input shaft bearing cups.
36. Using the special tools, remove the input shaft seal.
    Fig 34: Remove Input Shaft Seal Using Special Tool

    Courtesy of FORD MOTOR CO.
NOTE: Flywheel housing side shown, transaxle case side similar.
Fig 35: Removing Output Shaft Bearing Cups
Courtesy of FORD MOTOR CO.
37. Remove the output shaft bearing cups.
38. Remove the funnel.
    Fig 36: Removing Funnel

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39. Remove the shift control selector plate and spacer.
    1. Remove the bolts.
    2. Remove the shift control selector plate and spacer.
       Fig 37: Removing Bolts

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40. Remove the shift control shaft selector lever.
    1. Remove the bolt.
    2. Remove the shift control shaft selector lever.
       Fig 38: Removing Shift Control Shaft Selector Lever

       Courtesy of FORD MOTOR CO.
41. Remove and discard the roll pin.
    Fig 39: Locating Roll Pin

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42. Remove the shift control shaft assembly.
    Fig 40: Removing Shift Control Shaft Assembly

    Courtesy of FORD MOTOR CO.
43. Using the special tool, remove the shift control shaft seal.
    Fig 41: Removing Shift Control Shaft Seal Using Special Tool

    Courtesy of FORD MOTOR CO.
44. Remove the vent tube.
    1. Remove the bolts.
    2. Remove the vent tube.
       Fig 42: Locating Vent Tube Bolts

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NOTE: Flywheel housing side shown, transaxle case side similar.
Fig 43: Removing Differential Bearing Cups Using Special Bolts
Courtesy of FORD MOTOR CO.
45. Using the special tools, remove the differential bearing cups.
46. Remove the discard the reverse lever roll pin.
    Fig 44: Locating Reverse Lever Roll Pin

    Courtesy of FORD MOTOR CO.
47. Remove the reverse lever shaft.
    1. Remove the reverse lever shaft.
    2. Remove the reverse lever.
       Fig 45: Removing Reverse Lever Shaft

       Courtesy of FORD MOTOR CO.
NOTE: Transaxle case side shown, flywheel housing side similar.
Fig 46: Removing Halfshaft Seals Using Special Tool
Courtesy of FORD MOTOR CO.
48. Using the special tool, remove the halfshaft seals.