Section 359 (Manual Transaxle): Disassembly: Transaxle: Disassembly

WARNING: This page is about a different car, the 2013 Ford Fiesta. However, it is still accessible from the selected car via links, so may be relevant.

Using the special tool, install the transaxle.

Fig 1: Installing Transaxle Using Special Tool
Courtesy of FORD MOTOR CO.
Remove the clutch slave cylinder.
1. Remove the 3 clutch slave cylinder bolts.
2. Remove the clutch slave cylinder.
  
  Fig 2: Locating Clutch Slave Cylinder Bolts
  Courtesy of FORD MOTOR CO.
Remove the Vehicle Speed Sensor (VSS).
1. Remove the retaining pin.
2. Remove the VSS.
  
  Fig 3: Identifying Vehicle Speed Sensor And Retaining Pin
  Courtesy of FORD MOTOR CO.
Remove the reversing lamp switch.

Fig 4: Locating Reversing Lamp Switch
Courtesy of FORD MOTOR CO.
Remove the gearshift cables shroud retainers and the gearshift cables shroud.

Fig 5: Locating Gearshift Cables Shroud And Retainers
Courtesy of FORD MOTOR CO.
Remove the selector lever.
1. Remove the protective cap.
2. Remove and discard the snap-ring and remove the selector lever.
  
  Fig 6: Identifying Selector Lever Protective Cap And Snap-Ring
  Courtesy of FORD MOTOR CO.
Remove the 2 gearshift cables bracket nuts and remove the gearshift cables bracket.

Fig 7: Locating Gearshift Cables Bracket Nuts
Courtesy of FORD MOTOR CO.
Remove the shift lever snap ring and remove the shift lever.

Fig 8: Locating Shift Lever Snap Ring
Courtesy of FORD MOTOR CO.
Remove the selector shaft interlock mechanism.

Fig 9: Locating Selector Shaft Interlock Mechanism
Courtesy of FORD MOTOR CO.
Remove the 5th gear cover bolts and remove the 5th gear cover.

Fig 10: Locating 5th Gear Cover Bolts
Courtesy of FORD MOTOR CO.
NOTE: Note the position of the components before removal.

Remove the 5th gear synchronizer unit and selector fork.
1. Remove and discard the circlip.
2. Remove and discard the roll pin.
  
  Fig 11: Removing Roll Pin
  Courtesy of FORD MOTOR CO.
NOTE: Note the position of the components before removal.

Disassemble the synchronizer assembly.

Fig 12: Disassembled View Of Synchronizer Assembly
Courtesy of FORD MOTOR CO.
Remove and discard the 5th gear snap ring and remove the mainshaft 5th gear.

Fig 13: Removing Mainshaft 5th Gear
Courtesy of FORD MOTOR CO.
Using the special tool, remove the input shaft 5th gear.

Fig 14: Removing Input Shaft 5th Gear Using Special Tool
Courtesy of FORD MOTOR CO.
NOTE: Do not strike directly on the gear housing mating surfaces or damage can occur.

Remove the 5th gear housing.
1. Remove and discard the 9 bolts and carefully separate the 5th gear housing sections by tapping lightly.
2. Using Motorcraft® Metal Surface Prep, clean the 5th gear housing mating surfaces.
  
  Fig 15: Identifying 5th Gear Housing Mating Surface And Bolt
  Courtesy of FORD MOTOR CO.
Remove the input shaft and output shaft retaining rings.
1. Remove and discard the input shaft retaining ring.
2. Remove and discard the output shaft retaining ring.
  
  Fig 16: Identifying Input And Output Shaft Retaining Ring
  Courtesy of FORD MOTOR CO.
Remove the LH and RH halfshaft seals.
NOTE: Do not use metal scrapers to clean the transaxle gear housing surfaces or damage can occur.

NOTE: Slightly turn the transaxle housing to raise it.

Separate the transaxle housing from the clutch housing.
- Using Motorcraft® Metal Surface Prep, clean the transaxle housing and clutch housing mating surfaces.
  
  Fig 17: Locating Transaxle To Clutch Housing Bolts And Stud
  Courtesy of FORD MOTOR CO.
Remove the upper snap-ring from the selector rod guide sleeve.
1. Remove and discard the upper snap-ring.
2. Push the selector rod guide sleeve downwards.
  
  Fig 18: Removing Selector Rod Guide Sleeve
  Courtesy of FORD MOTOR CO.
Remove the selector rod guide sleeve.
1. Remove and discard the lower snap-ring from the guide sleeve.
2. Pull off the selector rod guide sleeve.
  
  Fig 19: Removing Selector Rod Guide Sleeve
  Courtesy of FORD MOTOR CO.
NOTE: Install a rubber belt to the auxiliary selector shaft to aid disassembly.

Remove the input and output shaft with the shift forks.

Fig 20: Removing Input And Output Shaft With Shift Forks
Courtesy of FORD MOTOR CO.
Remove the differential and the magnet.

Fig 21: Locating Differential And Magnet
Courtesy of FORD MOTOR CO.
Remove the reverse idle gear.

Fig 22: Locating Reverse Idle Gear
Courtesy of FORD MOTOR CO.
Remove the selector rod and locking plate.
1. Remove the selector interlock plate.
2. Remove the 5th/reverse gear selector rod.
  
  Fig 23: Identifying 5th/Reverse Gear Selector Rod And Selector Interlock Plate
  Courtesy of FORD MOTOR CO.
Remove and discard the input shaft oil seal.

Fig 24: Locating Input Shaft Oil Seal
Courtesy of FORD MOTOR CO.
Remove output shaft roller bearing.
- Press out the track rollers from the bearing cage.
- Remove the bearing cage.
  
  Fig 25: Locating Bearing Cage Track Rollers
  Courtesy of FORD MOTOR CO.
NOTE: Only use the special tool in the position indicated, otherwise the blanking plug will be forced out of the housing.

Using the special tool, remove the output shaft bearing cone.
- Remove the oil thrower.
  
  Fig 26: Removing Output Shaft Bearing Cone Using Special Tool
  Courtesy of FORD MOTOR CO.
Remove the bearing cone.

Fig 27: Removing Bearing Cone
Courtesy of FORD MOTOR CO.
Using the special tool, remove the differential bearing cone.

Fig 28: Removing Differential Bearing Cone Using Special Tool
Courtesy of FORD MOTOR CO.