Manual Transmission: Assembly: Transaxle

SPECIAL TOOL

Courtesy of FORD MOTOR CO.	Adapter Handle 205-153 (T80T-4000-W)
Courtesy of FORD MOTOR CO.	Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C)
Courtesy of FORD MOTOR CO.	Installer, Oil Seal 308-097 (T85T-7011-A)
Courtesy of FORD MOTOR CO.	Installer, Output Shaft Seal 308-579 or equivalent

MATERIAL SPECIFICATION

Item	Specification
Silicone Gasket and Sealant TA-30	WSE-M4G323-A4

Fig 1: Exploded View Of Transaxle

Courtesy of FORD MOTOR CO.

Fig 2: Transaxle Component Description

Courtesy of FORD MOTOR CO.

CAUTION: Assembly should only be carried out in a clean environment or damage to the transaxle may occur.

CAUTION: Be careful not to scratch the sliding face or mating faces or damage to the transaxle may occur.

CAUTION: Visually inspect all parts for any damage, deformation or abnormal wear. Install new parts only if unsuitable or damage to the transaxle may occur.

CAUTION: Do not work on the transaxle with cotton gloves. Cotton threads could become dislodged and damage to the transaxle may occur.

CAUTION: Install all new retaining pins, oil seals, and bearings or damage to the transaxle may occur.

CAUTION: Make sure to clean the old sealant from the mating threads of any sealed bolt or damage to the transaxle may occur.

1. Using the special tools, install a new input shaft oil seal.
   Fig 3: Installing Input Shaft Oil Seal

   Courtesy of FORD MOTOR CO.
2. Using the special tool, install a new RH intermediate shaft oil seal.
   Fig 4: Installing New RH Intermediate Shaft Oil Seal

   Courtesy of FORD MOTOR CO.
3. Install the funnel.
4. Install the mainshaft bearing.
5. Install the mainshaft bearing retainer and bolt.
CAUTION: Do not exceed 120°C (248°F) or damage to the clutch housing may occur.
6. Heat the clutch housing to 100°C (212°F) and install a new differential side bearing outer race.
7. Install the differential assembly.
CAUTION: Make sure to install the mainshaft straight in. Failure to install the mainshaft correctly may result in damage to the funnel on the clutch housing.
8. Install the input shaft assembly, mainshaft assembly, and reverse gear idler shaft assembly as a set.
9. Install the 1st/2nd gear shift fork.
10. Install the 1st/2nd gear shift rod.
11. Install a new 1st/2nd gear shift fork roll pin.
12. Install the 1st/2nd gear shift finger.
13. Install a new 1st/2nd gear shift finger roll pin.
14. Install the 1st/2nd gear check sleeve.
15. Install the 3rd/4th gear shift finger.
16. Install the 3rd/4th gear shift fork.
17. Install the 3rd/4th gear shift rod.
18. Install 2 new circlips.
    Fig 5: Locating Circlips

    Courtesy of FORD MOTOR CO.
19. Install a new 3rd/4th gear shift finger roll pin.
20. Install the 3rd/4th gear shift rod roll pin.
21. Install the 2 interlock pins.
22. Install the 5th/reverse gear bracket.
23. Install the 5th/reverse gear shift rod.
24. Install 2 new circlips.
    Fig 6: Locating Circlips

    Courtesy of FORD MOTOR CO.
25. Install the 5th gear shift fork.
26. Install a new 5th gear shift fork roll pin.
27. Install the reverse gear shift fork.
28. Install the reverse gear shift fork rod.
29. Install the shifter cap.
30. Lift the reverse gear shift fork and insert the cam part of the 5th/reverse gear bracket into the reverse level bracket.
    Fig 7: Inserting Cam Part Of Reverse Gear Bracket Into Reverse Level Bracket

    Courtesy of FORD MOTOR CO.
31. Install the reverse lever bracket bolts.
    • Tighten to 14 Nm (10 lb-ft).
32. Install the magnet.
33. Install a new LH halfshaft oil seal.
34. Install a new plug.
35. Using a depth micrometer and a straightedge, measure and record the depth from the mating surface of the transaxle case to the differential side bearing adjustment shim mounting surface. Record this measurement as L1.
    Fig 8: Measuring Depth From Mating Surface Of Transaxle Case To Differential Side Bearing

    Courtesy of FORD MOTOR CO.
36. Using a depth micrometer and a straightedge, measure and record the depth from the mating surface of the clutch housing to the differential side bearing outer race outer surface. Record this measurement as L2.
    • Install the differential side bearing outer race on the differential bearing.
    • Holding the outer race in position using hand pressure, rotate the differential 5 times to seat the bearing races.
      Fig 9: Measuring Depth From Mating Surface Of Clutch Housing To Differential Side Bearing

      Courtesy of FORD MOTOR CO.
NOTE: Do not use more than 2 shims to achieve the desired shim thickness.
NOTE: Shims are available in thicknesses from 0.48-0.92 mm (0.0189-0.0366 in) in 0.04 mm (0.00157 in) increments.
37. Select the shims to allow a preload of 0.15-0.21 mm (0.0059-0.0083 in) using the following formula: shim thickness = (L1-L2) + preload.
38. Install the differential side bearing adjustment shim.
CAUTION: Do not exceed 120°C (248°F) or damage to the transaxle case may occur.
39. Heat the transaxle case to 100°C (212°F) and install a new differential side bearing outer race.
40. Temporarily install the mainshaft, mainshaft bearing and circlip.
41. Temporarily assemble the transaxle case.
42. Temporarily install and tighten the transaxle case bolts
43. Using the special tool, measure and record the depth of the transaxle case to the mainshaft bearing surface when the circlip is expanded and mainshaft is raised to contact the transaxle case.
    Fig 10: Identifying Special Tool

    Courtesy of FORD MOTOR CO.
44. Release the circlip and allow the mainshaft to lower and engage the circlip. Measure and record the depth of the transaxle case to the mainshaft bearing surface.
NOTE: Do not use more than one shim to achieve the desired shim thickness.
NOTE: Shims are available in thicknesses from 0.44-1.08 mm (0.017-0.043 in) in 0.04 mm (0.00157 in) increments.
45. Select the correct shim to allow an end play of 0.00-0.06 mm (0.00-0.0024 in).
46. Remove the transaxle case.
47. Install the mainshaft adjustment shim.
48. Install a new snap ring.
49. Using a depth micrometer and a straightedge, measure and record the depth from the mating surface of the transaxle case to the input shaft adjustment shim mounting surface. Record this measurement as L1.
    Fig 11: Measuring Depth From Mating Surface Of Transaxle Case To Input Shaft

    Courtesy of FORD MOTOR CO.
50. Using a depth micrometer and a straightedge, measure and record the depth from the mating surface of the clutch housing to the input shaft bearing outer race outer surface. Record this measurement as L2.
    Fig 12: Measuring Depth From Mating Surface Of Clutch Housing To Input Shaft Bearing

    Courtesy of FORD MOTOR CO.
NOTE: Do not use more than one shim to achieve the desired shim thickness.
NOTE: Shims are available in thicknesses from 0.40-1.72 mm (0.016-0.068 in) in 0.04 mm (0.00157 in) increments.
51. Select the shims to allow an end play of 0.00-0.06 mm (0.00-0.0024 in) using the following formula: shim thickness = (L1-L2) - end play.
52. Install the input shaft adjustment shim.
53. Using a depth micrometer and a straightedge, measure and record the depth from the mating surface of the transaxle case to the reverse idler shaft adjustment shim mounting surface. Record this measurement as L1.
    Fig 13: Measuring Depth From Mating Surface Of Transaxle Case To Reverse Idler Shaft

    Courtesy of FORD MOTOR CO.
54. Using a depth micrometer and a straightedge, measure and record the depth from the mating surface of the clutch housing to the reverse idler shaft bearing surface. Record this measurement as L2.
    Fig 14: Measuring Depth From Mating Surface Of Clutch Housing To Reverse Idler Shaft

    Courtesy of FORD MOTOR CO.
NOTE: Do not use more than one shim to achieve the desired shim thickness.
NOTE: Shims are available in thicknesses from 1.76-2.64 mm (0.069-0.104 in) in 0.04 mm (0.00157 in) increments.
55. Select the shims to allow an end play of 0.04-0.14 mm (0.001-0.005 in) using the following formula: shim thickness = (L1-L2) - end play.
56. Install the reverse idler shaft adjustment shim.
57. Install the oil gutter.
58. Install the baffle plate.
59. Apply a continuous bead of silicone gasket and sealant.
    Fig 15: Locating Bead Of Silicone Gasket

    Courtesy of FORD MOTOR CO.
60. Spread the circlip and install the transaxle case.
61. Install a new bore plug.
NOTE: The black colored bolt must be installed new, in the correct position, and tightened to 65 Nm (48 lb-ft).
62. Install the transaxle case bolts.
    • Tighten to 52 Nm (38 lb-ft) in a cross pattern.
      Fig 16: Locating Transaxle Case Bolts

      Courtesy of FORD MOTOR CO.
63. Install the 3 check balls.
64. Install the 5th/reverse gear shift check sleeve.
65. Install the springs. Refer to the following table for the correct color and location:
    COLOR REFERENCE CHART
    
    

    Color	Location
    Yellow	5th/reverse gear shift rod
    Blue	3rd/4th gear shift rod
    White	1st/2nd gear shift rod

66. Install a new check plug in the 5th/reverse gearshift rod.
67. Install new check plugs in the 1st/2nd gear shift rod and the 3rd/4th gear shift rod.
68. Install a new shift assembly O-ring seal.
69. Install the shift assembly.
70. Install 4 new shift assembly bolts.
    • Tighten to 7 Nm (62 lb-in).
71. Install a new stopper bolt.
    • Tighten to 28 Nm (21 lb-ft).
72. Install a new shift check bolt.
    • Tighten to 24 Nm (18 lb-ft).
73. Install a new breather.
74. Install the reverse switch.
75. Install the neutral switch.
76. Install the transaxle drain plug, the fill plug, and the fill level inspection plug.
    • Install new plug washers.
    • Tighten the drain plug and the fill level inspection plug to 35 Nm (26 lb-ft).
    • Tighten the transaxle fill plug to 35 Nm (26 lb-ft).