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Removal And Installation: Transaxle: Disassembly

  1. Remove the transaxle from the vehicle. For additional information, refer to TRANSAXLE  in this information.
  2. Remove the transaxle wiring harness.
    NOTE: Take note of the wiring harness clip locations for installation.
    Fig 1: Locating Wiring Harness Clip
    G06939527Courtesy of FORD MOTOR CO.
  3. Remove the Transmission Control Module (TCM). For additional information, refer to TRANSMISSION CONTROL MODULE (TCM)  in this information.
  4. Remove the Transmission Range (TR) sensor. For additional information, refer to TRANSMISSION RANGE (TR) SENSOR  in this information.
  5. Remove the Output Shaft Speed (OSS) sensor. For additional information, refer to OUTPUT SHAFT SPEED (OSS) SENSOR  in this information.
  6. Remove 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.
  7. Remove the clutch engagement system. For additional information, refer to CLUTCH ENGAGEMENT SYSTEM  in this information.
  8. Remove the guide tube bolts.
    Fig 2: Locating Guide Tube Bolts
    G06939528Courtesy of FORD MOTOR CO.
  9. Remove the guide tube.
    Fig 3: Locating Guide Tube
    G06939529Courtesy of FORD MOTOR CO.
  10. Using the special tools, remove and discard the input shaft seal.
    Fig 4: Removing Outer Input Shaft Case Seal Using Special Tools
    G06939530Courtesy of FORD MOTOR CO.
  11. Remove and discard the input shaft snap ring.
    Fig 5: Locating Input Shaft Snap Ring
    G06939531Courtesy of FORD MOTOR CO.
  12. Remove the manual control lever bolt and discard and remove the manual control lever.
    Fig 6: Locating Manual Control Lever Bolt
    G06939532Courtesy of FORD MOTOR CO.
  13. Remove the top 3 transaxle case bolts.
    Fig 7: Locating Top Transaxle Case Bolts
    G06939533Courtesy of FORD MOTOR CO.
  14. Remove the bottom 18 transaxle case bolts (14 shown in illustration).
    Fig 8: Locating Transaxle Case Bolts
    G06939534Courtesy of FORD MOTOR CO.
  15. Install the special tool.
    Fig 9: Installing Special Tool
    G06939535Courtesy of FORD MOTOR CO.
  16. Install the special tools and special tools bolts.
    NOTE: Install the special tools in the position shown in illustration.
    • Tighten to 18 Nm (159 lb-in).
      Fig 10: Locating Special Tools Bolts
      G06939536Courtesy of FORD MOTOR CO.
  17. Turn the special tool bolt approximately 20 turns to separate the clutch housing from the transaxle case.
    Fig 11: Turning Special Tool Bolt To Clutch Housing From Transaxle Case
    G06939537Courtesy of FORD MOTOR CO.
  18. Lift the clutch housing off the transaxle case.
    Fig 12: Locating Clutch Housing
    G06939538Courtesy of FORD MOTOR CO.
  19. Remove the differential.
    Fig 13: Locating Differential
    G06939539Courtesy of FORD MOTOR CO.
  20. Remove the park pawl actuation shaft assembly.
    Fig 14: Locating Park Pawl Actuation Shaft Assembly
    G06939540Courtesy of FORD MOTOR CO.
  21. Remove the park pawl rod and park pawl.
    Fig 15: Locating Park Pawl Rod And Park Pawl
    G06939541Courtesy of FORD MOTOR CO.
  22. Remove the large clock gears and pins.
    Fig 16: Locating Large Clock Gears And Pins
    G06939542Courtesy of FORD MOTOR CO.
  23. Remove the small clock gears and pins.
    Fig 17: Locating Small Clock Gears And Pins
    G06939543Courtesy of FORD MOTOR CO.
  24. Remove the magnet.
    Fig 18: Locating Magnet
    G06939544Courtesy of FORD MOTOR CO.
  25. Install the special tool.
    Fig 19: Identifying Special Tool
    G06939545Courtesy of FORD MOTOR CO.
  26. Flip the transaxle case assembly over on the special tool.
    Fig 20: Identifying Transaxle Case Assembly On Special Tool
    G06939546Courtesy of FORD MOTOR CO.
  27. Remove the special tool.
    Fig 21: Identifying Special Tools
    G06939547Courtesy of FORD MOTOR CO.
  28. Remove the 6 output shaft bearing retainer bolts.
    Fig 22: Locating Output Shaft Bearing Retainer Bolts
    G06939548Courtesy of FORD MOTOR CO.
  29. Lift the transaxle case off the gearset assemblies.
    Fig 23: Locating Transaxle Case
    G06939549Courtesy of FORD MOTOR CO.
  30. Remove the park plunger plug.
    Fig 24: Locating Park Plunger Plug
    G06939550Courtesy of FORD MOTOR CO.
  31. Remove the park plunger.
    Fig 25: Locating Park Plunger
    G06939551Courtesy of FORD MOTOR CO.
  32. Remove the oil spout.
    Fig 26: Locating Oil Spout
    G06939552Courtesy of FORD MOTOR CO.
  33. Remove the shift fork shafts.
    Fig 27: Removing Shift Fork Shafts
    G06939553Courtesy of FORD MOTOR CO.
  34. Remove the shift drums.
    Fig 28: Locating Shift Drums
    G06939554Courtesy of FORD MOTOR CO.
  35. Remove the shift forks.
    Fig 29: Locating Shift Forks
    G06939555Courtesy of FORD MOTOR CO.
  36. Install the special tool.
    Fig 30: Identifying Special Tool
    G06939556Courtesy of FORD MOTOR CO.
  37. Flip the gearset assembly over on its side.
    Fig 31: Identifying Gearset Assembly On Side
    G06939557Courtesy of FORD MOTOR CO.
  38. Remove the special tool.
    Fig 32: Identifying Special Tool
    G06939558Courtesy of FORD MOTOR CO.
  39. Remove output shaft 1 by removing the special tool.
    Fig 33: Removing Output Shaft
    G06939559Courtesy of FORD MOTOR CO.
  40. Remove the input shaft assembly by removing the special tool.
    Fig 34: Removing Input Shaft Assembly
    G06939560Courtesy of FORD MOTOR CO.
  41. Remove the special tool from output shaft 2.
    Fig 35: Removing Special Tool From Output Shaft
    G06939561Courtesy of FORD MOTOR CO.
  42. Remove the hollow input shaft from the solid input shaft.
    Fig 36: Removing Hollow Input Shaft From Solid Input Shaft
    G06939562Courtesy of FORD MOTOR CO.
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