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Removal And Installation: Transaxle: Assembly

  1. Install the hollow input shaft onto the solid input shaft.
    NOTE: Make sure not to damage the inner input shaft seal or bearing.
    Fig 1: Installing Hollow Input Shaft On Solid Input Shaft
    G06939563Courtesy of FORD MOTOR CO.
  2. Install output shaft 2 on the special tool.
    NOTE: Make sure the synchronizers are in the neutral position.
    Fig 2: Installing Output Shaft On Special Tool
    G06939564Courtesy of FORD MOTOR CO.
  3. Install the input shaft on the special tool.
    Fig 3: Installing Input Shaft On Special Tool
    G06939565Courtesy of FORD MOTOR CO.
  4. Install output shaft 1 on the special tool.
    NOTE: Make sure the synchronizers are in the neutral position.
    Fig 4: Installing Output Shaft On Special Tool
    G06939566Courtesy of FORD MOTOR CO.
  5. Install the special tool.
    Fig 5: Identifying Special Tool
    G06939567Courtesy of FORD MOTOR CO.
  6. Flip the gearset assembly over onto the special tool.
    Fig 6: Identifying Gearset Assembly On Special Tool
    G06939568Courtesy of FORD MOTOR CO.
  7. Remove the special tool.
    Fig 7: Removing Special Tool
    G06939569Courtesy of FORD MOTOR CO.
  8. Install the 4th/reverse shift fork.
    Fig 8: Locating 4Th/Reverse Shift Fork
    G06939570Courtesy of FORD MOTOR CO.
  9. Install the 2nd/6th gear shift fork and linkage.
    Fig 9: Locating 2nd/6th Gear Shift Fork And Linkage
    G06939571Courtesy of FORD MOTOR CO.
  10. Install shift drum 1.
    NOTE: Make sure the shift drum is in the neutral position as shown in illustration.
    Fig 10: Locating Shift Drum
    G06939572Courtesy of FORD MOTOR CO.
  11. Install the 3rd gear linkage and shift drum 2.
    NOTE: Make sure the shift drum is in the neutral position as shown in illustration.
    Fig 11: Identifying 3rd Gear Linkage And Shift Drum
    G06939573Courtesy of FORD MOTOR CO.
  12. Install the 1st/5th gearshift fork
    Fig 12: Identifying 1st/5th Gearshift Fork
    G06939574Courtesy of FORD MOTOR CO.
  13. Install the 3rd gear shift fork.
    Fig 13: Locating 3rd Gear Shift Fork
    G06939575Courtesy of FORD MOTOR CO.
  14. Install the shift fork shafts.
    1. Install the small shift fork shafts.
    2. Install the large shift fork shafts.
      Fig 14: Identifying Shift Fork Shafts
      G06939576Courtesy of FORD MOTOR CO.
  15. Install the oil spout.
    Fig 15: Locating Oil Spout
    G06939577Courtesy of FORD MOTOR CO.
  16. Install the special tools.
    NOTE: Make sure the bearing retainer brackets are positioned as shown in illustration.
    Fig 16: Identifying Special Tools
    G06939578Courtesy of FORD MOTOR CO.
  17. Install the transaxle case onto the gearset assemblies.
    Fig 17: Locating Transaxle Case
    G06939579Courtesy of FORD MOTOR CO.
  18. Install the 6 bearing retainer bolts.
    • Tighten to 32 Nm (24 lb-ft).
      Fig 18: Locating Bearing Retainer Bolts
      G06939580Courtesy of FORD MOTOR CO.
  19. Install the special tool.
    Fig 19: Identifying Special Tools
    G06939581Courtesy of FORD MOTOR CO.
  20. Flip the transaxle case assembly over onto the special tool.
    Fig 20: Identifying Transaxle Case Assembly On Special Tool
    G06939582Courtesy of FORD MOTOR CO.
  21. Remove the special tool.
    Fig 21: Identifying Special Tool
    G06939583Courtesy of FORD MOTOR CO.
  22. Install the magnet.
    Fig 22: Locating Magnet
    G06939584Courtesy of FORD MOTOR CO.
  23. Install the small clock gears and pins.
    Fig 23: Locating Small Clock Gears And Pins
    G06939585Courtesy of FORD MOTOR CO.
  24. Install the large clock gears and pins.
    Fig 24: Locating Large Clock Gears And Pins
    G06939586Courtesy of FORD MOTOR CO.
  25. Install the park pawl and park pawl rod.
    Fig 25: Locating Park Pawl Rod And Park Pawl
    G06939587Courtesy of FORD MOTOR CO.
  26. Install the park pawl actuation shaft assembly.
    NOTE: Make sure the pin is installed as shown in illustration.
    Fig 26: Locating Park Pawl Actuation Shaft Assembly
    G06939588Courtesy of FORD MOTOR CO.
  27. Install the differential.
    NOTE: If the differential bearings, differential, clutch housing and/or transaxle case are replaced refer to DIFFERENTIAL SHIM SELECTION  in this information.
    Fig 27: Locating Differential
    G06939589Courtesy of FORD MOTOR CO.
  28. Apply a 1 mm (0.039 in) bead of sealant around the inside of the bolt holes on the case side.
    NOTE: Make sure the transaxle case and the clutch housing are clean and no old sealant is present or transmission fluid leaks can occur and cause transaxle damage.
    Fig 28: Locating Transaxle Case And Clutch Housing
    G06939590Courtesy of FORD MOTOR CO.
  29. Using a 1500W heat gun, or equivalent, heat the input shaft bearing in the clutch housing for approximately 5 minutes.
    NOTE: Do not overheat the bearing or damage to the bearing may occur.
    Fig 29: Locating Input Shaft Bearing
    G06939591Courtesy of FORD MOTOR CO.
  30. Install the clutch housing.
    Fig 30: Locating Clutch Housing
    G06939592Courtesy of FORD MOTOR CO.
  31. Install the 18 bottom clutch housing-to-case bolts (14 shown in illustration).
    • Tighten to 27 Nm (20 lb-ft).
      Fig 31: Locating Bottom Clutch Housing-To-Case Bolts
      G06939593Courtesy of FORD MOTOR CO.
  32. Install the 3 top clutch housing-to-case bolts.
    • Tighten to 27 Nm (20 lb-ft).
      Fig 32: Locating Top Clutch Housing-To-Case Bolts
      G06939594Courtesy of FORD MOTOR CO.
  33. Install the park plunger.
    Fig 33: Locating Park Plunger
    G06939595Courtesy of FORD MOTOR CO.
  34. Install the park plunger plug.
    • Tighten to 43 Nm (32 lb-ft).
      Fig 34: Locating Park Plunger Plug
      G06939596Courtesy of FORD MOTOR CO.
  35. Install a new input shaft snap ring.
    Fig 35: Locating Input Shaft Snap Ring
    G06939597Courtesy of FORD MOTOR CO.
  36. Using the special tools, install a new input shaft seal.
    Fig 36: Installing Input Shaft Seal Using Special Tools
    G06939598Courtesy of FORD MOTOR CO.
  37. Using the locating flange on the guide tube, install the guide tube.
    Fig 37: Locating Guide Tube
    G06939599Courtesy of FORD MOTOR CO.
  38. Install the guide tube bolts.
    NOTE: The guide tube bolts must not project beyond the mounting surface of the clutch engagement levers.
    • Tighten to 8 Nm (71 lb-in).
      Fig 38: Locating Guide Tube Bolts
      G06939600Courtesy of FORD MOTOR CO.
  39. Install the clutch engagement system. For additional information, refer to CLUTCH ENGAGEMENT SYSTEM  in this information.
  40. Install the clutch. For additional information, refer to CLUTCH  in this information.
  41. Install the OSS  sensor. For additional information, refer to OUTPUT SHAFT SPEED (OSS) SENSOR  in this information.
  42. Install the input shaft speed sensors. For additional information, refer to INPUT SHAFT SPEED SENSOR - NO. 1  and INPUT SHAFT SPEED SENSOR - NO. 2  in this information.
  43. Install the TR  sensor. For additional information, refer to TRANSMISSION RANGE (TR) SENSOR  in this information.
  44. Install the transaxle into the vehicle. For additional information, refer to TRANSAXLE  in this information.
  45. Perform the TCM  Adaptive Learning procedure. Refer to TRANSMISSION CONTROL MODULE (TCM) ADAPTIVE LEARNING  in this information.
  46. Perform the Clutch Adaptive Learning procedure. Refer to CLUTCH ADAPTIVE LEARNING  in this information.
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