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Section 359 (Manual Transaxle): Assembly: Transaxle: Assembly

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.
  1. NOTE: Apply transmission fluid to all rotating surfaces.

    Clean and check all parts carefully before reassembly.

  2. Using the special tool, install the output shaft roller bearing and bearing cone.
    1. Install the oil thrower.
    2. Install the bearing as far as stop.
      Fig 1: Installing Output Shaft Roller Bearing And Bearing Cone Using Special Tool
      G08867486Courtesy of FORD MOTOR CO.
  3. Using the special tool, install the differential bearing cone.
    Fig 2: Installing Differential Bearing Cone Using Special Tool
    G08867487Courtesy of FORD MOTOR CO.
  4. Install the shift selector interlock plate and the selector rod.
    1. Install the shift selector interlock plate.
    2. Install the 5th/reverse gear selector rod.
      Fig 3: Identifying 5th/Reverse Gear Selector Rod And Selector Interlock Plate
      G08867488Courtesy of FORD MOTOR CO.
  5. Install the reverse gear idler (as shown in illustration), the differential and the magnet.
    1. Reverse gear idler.
    2. Differential.
    3. Magnet.
      Fig 4: Locating Reverse Gear Idler Installation Position
      G08867489Courtesy of FORD MOTOR CO.
  6. Prepare the input and the output shaft for installation.
    1. Position the input shaft and the output shaft together.
    2. Position the 1st and 2nd gear selector fork on the shaft assemblies.
    3. Position the 3rd and 4th gear selector fork on the shaft assemblies.
      Fig 5: Locating Input And Output Shaft
      G08867490Courtesy of FORD MOTOR CO.
  7. Install the input shaft, output shaft and selector fork assemblies into the transaxle case.
    • Install a rubber band to the selector shaft to aid assembly.
    • Insert the input shaft to a depth of approximately 50 mm (1.968 in) and swivel it slightly to the side.
    • Insert the output shaft to the level of the input shaft and engage the gears.
    • Install the input shaft and the output shaft.
      Fig 6: Installing Input And Output Shaft Into Transaxle Case
      G08867491Courtesy of FORD MOTOR CO.
  8. Install the selector shaft guide sleeve and new lower snap ring.
    1. Push in the selector shaft guide sleeve.
    2. Install the new lower snap ring.
      Fig 7: Pushing Selector Shaft Guide Sleeve
      G08867492Courtesy of FORD MOTOR CO.
  9. Install the selector shaft guide sleeve new upper snap ring.
    1. Pull up the selector shaft guide sleeve.
    2. Install the new upper snap ring.
      Fig 8: Pulling Up Selector Shaft Guide Sleeve
      G08867493Courtesy of FORD MOTOR CO.
  10. Move the inner gearshift linkage to 5th gear.
    • Turn the selector shaft clockwise until the reverse and 5th gear passage is reached, then press downwards.
      Fig 9: Moving Inner Gearshift Linkage To 5th Gear
      G08867494Courtesy of FORD MOTOR CO.
  11. NOTE: The inner diameters of the Belleville washers are touching.

    Install the shim and secure it by staking the edge of the housing.

    1. Belleville washers.
    2. Shim.
    3. Install the bearing cone and secure it by staking the edge of the housing.
      Fig 10: Locating Belleville Washers And Shim
      G08867495Courtesy of FORD MOTOR CO.
  12. Apply Gasket Maker to the transaxle housing.
    Fig 11: Locating Gasket Maker Applying Areas On Transaxle Housing
    G08867496Courtesy of FORD MOTOR CO.
  13. Install the transaxle housing bolts and evenly tighten.
    • Tighten to 33 Nm (24 lb-ft).
      Fig 12: Locating Transaxle Housing Bolts
      G08867497Courtesy of FORD MOTOR CO.
  14. NOTE: Use a wooden block.

    Install the new input shaft and output shaft retaining rings.

    Fig 13: Installing Input And Output Shaft Retaining Rings Using Tool
    G08867498Courtesy of FORD MOTOR CO.
  15. NOTE: Turn the retaining rings so that they are located in the cut-outs in the gasket.

    Install the special tools.

    Fig 14: Locating Retaining Rings
    G08867499Courtesy of FORD MOTOR CO.
  16. Install the new 5th gear housing gasket, 5th gear housing and the 9 new 5th gear housing bolts.
    • Tighten to 17 Nm (150 lb-in).
      Fig 15: Locating 5th Gear Housing Gasket And Mounting Bolts
      G08867500Courtesy of FORD MOTOR CO.
  17. NOTE: Remove the transaxle from the special tool and carry out the following step on a press.
    NOTE: Install an anti twist stop for the selector rod.
    NOTE: The transaxle housing must not rest on the press table. Support the input shaft clutch splines on the press.

    Using the special tool and a press, install the 5th gear wheel onto the input shaft.

    Fig 16: Installing 5th Gear Wheel On Input Shaft Using Special Tool And Press
    G08867501Courtesy of FORD MOTOR CO.
  18. Install the special tool onto the transaxle.
    Fig 17: Installing Special Tool On Transaxle
    G08867502Courtesy of FORD MOTOR CO.
  19. Using the special tool, install the new 5th gear snap ring.
    1. Install the new snap ring onto the special tool.
    2. Install the special tool and push on the new snap ring.
      Fig 18: Installing 5th Gear Snap Ring Using Special Tool
      G08867503Courtesy of FORD MOTOR CO.
  20. Install the mainshaft 5th gear.
    Fig 19: Locating Mainshaft 5th Gear
    G08867504Courtesy of FORD MOTOR CO.
  21. NOTE: Make sure that the components are installed to the position noted before removal.

    Assemble the synchronizer hub and sleeve.

    Fig 20: Inspecting Synchronizer Hub And Sleeve Components Installation Position
    G08867505Courtesy of FORD MOTOR CO.
  22. NOTE: Make sure that the components are installed to the position noted before removal.

    Install the synchronizer actuators.

    Fig 21: Inspecting Synchronizer Actuator Installation Position
    G08867506Courtesy of FORD MOTOR CO.
  23. NOTE: Make sure that the components are installed to the position noted before removal.

    Install the synchronizer radial spring.

    Fig 22: Inspecting Synchronizer Radial Spring Installation Position
    G08867507Courtesy of FORD MOTOR CO.
  24. NOTE: Make sure that the components are installed to the position noted before removal.

    Install the synchronizer ring.

    Fig 23: Inspecting Synchronizer Ring Installation Position
    G08867508Courtesy of FORD MOTOR CO.
  25. Install the synchronizer and selector fork.
    1. Align the marks made during removal.
    2. Install the new circlip.
    3. Install the new roll pin.
      Fig 24: Installing Roll Pin
      G08867509Courtesy of FORD MOTOR CO.
  26. Apply Silicone Gasket and Sealant evenly to the end cap.
    Fig 25: Applying Silicone Gasket And Sealant On End Cap
    G08867510Courtesy of FORD MOTOR CO.
  27. Install the 5th gear cover and the 5th gear cover bolts.
    • Tighten to 12 Nm (106 lb-in).
      Fig 26: Locating 5th Gear Cover Bolt
      G08867511Courtesy of FORD MOTOR CO.
  28. NOTE: Install the selector shaft interlock in the neutral position.

    Install the selector shaft interlock as shown in illustration.

    Fig 27: Locating Selector Shaft Interlock Installation Position
    G08867512Courtesy of FORD MOTOR CO.
  29. NOTE: Make sure the selector shaft interlock in the neutral position.

    Apply Threadlock and Sealer to the selector interlock mechanism and install.

    • Tighten to 25 Nm (18 lb-ft).
      Fig 28: Locating Selector Shaft Interlock
      G08867513Courtesy of FORD MOTOR CO.
  30. Install the shift lever.
    Fig 29: Locating Shift Lever
    G08867514Courtesy of FORD MOTOR CO.
  31. Using the special tool, install the halfshaft seal until it engages audibly.
    Fig 30: Installing Halfshaft Seal Using Special Tool
    G08867515Courtesy of FORD MOTOR CO.
  32. Engage 5th gear.
    • Turn the selector shaft clockwise as far as possible and press it in.
      Fig 31: Turning Selector Shaft Clockwise
      G08867516Courtesy of FORD MOTOR CO.
  33. Install the gearshift cables bracket and the gearshift cables bracket nuts.
    • Tighten to 20 Nm (177 lb-in).
      Fig 32: Locating Gearshift Cables Bracket Nuts
      G08867517Courtesy of FORD MOTOR CO.
  34. Install the selector lever.
    1. Install the new snap ring.
    2. Install the protective cap.
      Fig 33: Identifying Selector Lever Protective Cap And Snap Ring
      G08867518Courtesy of FORD MOTOR CO.
  35. Install the gearshift cables shroud and gearshift cables shroud fasteners.
    Fig 34: Locating Gearshift Cables Shroud And Retainers
    G08867519Courtesy of FORD MOTOR CO.
  36. Install the reversing lamp switch.
    • Tighten to 14 Nm (124 lb-in).
      Fig 35: Locating Reversing Lamp Switch
      G08867520Courtesy of FORD MOTOR CO.
  37. Install the Vehicle Speed Sensor (VSS).
    1. Connect the VSS.
    2. Install the retaining pin.
      Fig 36: Identifying Vehicle Speed Sensor And Retaining Pin
      G08867521Courtesy of FORD MOTOR CO.
  38. NOTE: Apply adhesive tape to cover the input shaft splines to prevent damage to the input shaft seal.

    Using the special tools, install the new input shaft seal.

    1. Apply a small amount of adhesive tape to the input shaft.
    2. Put the input shaft seal on the input shaft.
    3. Using the special tool, install the new input shaft seal.
      Fig 37: Installing Input Shaft Seal Using Special Tool
      G08867522Courtesy of FORD MOTOR CO.
  39. Install the clutch slave cylinder and the clutch slave cylinder bolts.
    1. Apply a small amount of grease to the input shaft.
    2. Install the clutch slave cylinder.
    3. Install the 3 clutch slave cylinder bolts.
      • Tighten evenly to 11 Nm (97 lb-in).
        Fig 38: Identifying Input Shaft, Clutch Slave Cylinder And Bolts
        G08867523Courtesy of FORD MOTOR CO.
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