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Disassembly And Assembly: Transaxle: Disassembly

  1. NOTE: Take note of the transmission wiring harness clip locations for installation.

    Remove the transmission wiring harness.

    Fig 1: Locating Transmission Wiring Harness And Clips
    G08867114Courtesy of FORD MOTOR CO.
  2. Remove the 4 Transmission Control Module (TCM) bolts.
    Fig 2: Locating TCM Mounting Bolts
    G08867115Courtesy of FORD MOTOR CO.
  3. Using a flat blade screwdriver, carefully pry the TCM from the transmission, at the location shown in illustration, and remove the TCM, discard the O-rings.
    Fig 3: Removing TCM Using Flat Blade Screwdriver
    G08867116Courtesy of FORD MOTOR CO.
  4. Remove the 2 Transmission Range (TR) sensor bolts and the TR sensor.
    Fig 4: Locating Transmission Range Sensor And Mounting Bolts
    G08867117Courtesy of FORD MOTOR CO.
  5. Remove the Output Shaft Speed (OSS) sensor bolt and OSS sensor.
    Fig 5: Locating Output Shaft Speed Sensor And Mounting Bolt
    G08867118Courtesy of FORD MOTOR CO.
  6. Remove the input shaft speed sensor 1.
    1. Remove the input shaft speed sensor 1 bolt.
    2. Remove the input shaft speed sensor 1.
    3. Remove the input shaft speed sensor 1 shim.
      Fig 6: Identifying Input Shaft Speed Sensor 1, Shim And Bolt
      G08867119Courtesy of FORD MOTOR CO.
  7. Remove the input shaft speed sensor 2.
    1. Remove the input shaft speed sensor 2 bolt.
    2. Remove the input shaft speed sensor 2.
    3. Remove the input shaft speed sensor 2 shim.
      Fig 7: Identifying Input Shaft Speed Sensor 2, Shim And Bolt
      G08867120Courtesy of FORD MOTOR CO.
  8. Install the special tools.
    Fig 8: Installing Special Tools
    G08867121Courtesy of FORD MOTOR CO.
  9. Stand the transmission on its back.
  10. Remove the 4 clutch motor 1 bolts and remove clutch motor 1.
    Fig 9: Locating Clutch Motor 1 And Mounting Bolts
    G08867122Courtesy of FORD MOTOR CO.
  11. Remove the 4 clutch motor 2 bolts and remove clutch motor 2.
    Fig 10: Locating Clutch Motor 2 And Mounting Bolts
    G08867123Courtesy of FORD MOTOR CO.
  12. Remove and discard the clutch hub snap ring.
    Fig 11: Removing Clutch Hub Snap Ring
    G08867124Courtesy of FORD MOTOR CO.
  13. NOTE: Index mark the clutch hub and clutch for installation.

    Remove the clutch hub.

    Fig 12: Removing/Installing Clutch Hub
    G08867125Courtesy of FORD MOTOR CO.
  14. Install the special tools.
    Fig 13: Identifying Special Tools (307-675/1 And 307-675/4)
    G08867126Courtesy of FORD MOTOR CO.
  15. Using the special tools, turn the center bolt of the special tool with a maximum of 5 Nm (44 lb-in) of torque to push the clutch down to release the pressure from the hollow input shaft snap ring.
    Fig 14: Installing Special Tools Onto Transaxle Case
    G08867127Courtesy of FORD MOTOR CO.
  16. Remove and discard the hollow input shaft snap ring.
    Fig 15: Removing Hollow Input Shaft Snap Ring
    G08867128Courtesy of FORD MOTOR CO.
  17. NOTE: Make sure the lifting legs are installed on the 3 clutch studs marked with the manufacturing mark as shown in illustration.
    NOTE: Make sure the lifting leg with the angle is in the location shown in illustration.

    Install the special tools.

    Fig 16: Locating Lifting Legs Installation Position
    G08867129Courtesy of FORD MOTOR CO.
  18. Install the special tools.
    Fig 17: Locating Special Tool Mounting Nuts
    G08867130Courtesy of FORD MOTOR CO.
  19. Turn the center bolt of the special tool with approximately 5 Nm (44 lb-in) of torque until the clutch is free of the input shaft.
    Fig 18: Locating Center Bolt Of Special Tool
    G08867131Courtesy of FORD MOTOR CO.
  20. Using the special tools, remove the clutch as an assembly from the transmission.
    Fig 19: Removing Clutch Assembly From Transaxle Using Special Tools
    G08867132Courtesy of FORD MOTOR CO.
  21. Using the special tool, remove and discard the inner input shaft seal.
    Fig 20: Removing Inner Input Shaft Seal Using Special Tool
    G08867133Courtesy of FORD MOTOR CO.
  22. Remove the Z-washers from the engagement system bearing unit.
    Fig 21: Locating Engagement System Bearing Unit Z-Washers
    G08867134Courtesy of FORD MOTOR CO.
  23. NOTE: The engagement system bearing unit should be removed easily.

    Remove the engagement system bearing unit. Inspect for wear or damage. Replace as necessary.

    Fig 22: Removing Engagement System Bearing Unit
    G08867135Courtesy of FORD MOTOR CO.
  24. NOTE: Remove the spring retainer bolts by loosening them slightly in an alternating pattern or damage can occur to the clutch actuator levers.
    NOTE: The spring retainers and actuator levers are matched sets with corresponding serial numbers. If the spring retainers and actuator levers are being reused, mark on each spring retainer and actuator lever for assembly.

    Remove the 4 spring retainer bolts from the spring retainers and remove the spring retainers.

    Fig 23: Locating Spring Retainer Bolts
    G08867136Courtesy of FORD MOTOR CO.
  25. Install clutch actuator lever locks as shown in illustration if available.
    Fig 24: Locating Clutch Actuator Lever Locks
    G08867137Courtesy of FORD MOTOR CO.
  26. Remove the 2 bolts from the clutch actuator lever 1.
    Fig 25: Locating Clutch Actuator Lever Mounting Bolts
    G08867138Courtesy of FORD MOTOR CO.
  27. Remove the 2 bolts from the clutch actuator lever 2.
    Fig 26: Locating Clutch Actuator Lever Mounting Bolts
    G08867139Courtesy of FORD MOTOR CO.
  28. NOTE: Be sure to properly handle the actuator lever as shown in illustration or damage may occur.

    Remove the clutch actuator lever 1.

    Fig 27: Removing/Installing Clutch Actuator Lever
    G08867140Courtesy of FORD MOTOR CO.
  29. NOTE: Be sure to properly handle the actuator lever as shown in illustration or damage may occur.

    Remove the clutch actuator lever 2.

    Fig 28: Removing/Installing Clutch Actuator Lever
    G08867141Courtesy of FORD MOTOR CO.
  30. Remove the guide tube bolts.
    Fig 29: Locating Guide Tube Bolts
    G08867142Courtesy of FORD MOTOR CO.
  31. Remove the guide tube.
    Fig 30: Locating Guide Tube
    G08867143Courtesy of FORD MOTOR CO.
  32. Using the special tools, remove and discard the input shaft case seal.
    Fig 31: Removing Input Shaft Case Seal Using Special Tools
    G08867144Courtesy of FORD MOTOR CO.
  33. Remove and discard the input shaft snap ring.
    Fig 32: Removing Input Shaft Snap Ring
    G08867145Courtesy of FORD MOTOR CO.
  34. Remove discard the manual control lever bolt and remove the manual control lever.
    Fig 33: Removing Manual Control Lever Bolt
    G08867146Courtesy of FORD MOTOR CO.
  35. Remove the top 3 clutch housing-to-case bolts.
    Fig 34: Locating Clutch Housing-To-Case Bolts
    G08867147Courtesy of FORD MOTOR CO.
  36. Remove the bottom 18 clutch housing-to-case bolts (13 shown in illustration).
    Fig 35: Locating Clutch Housing-To-Case Bolts
    G08867148Courtesy of FORD MOTOR CO.
  37. Install the special tool.
    Fig 36: Installing Special Tool
    G08867149Courtesy of FORD MOTOR CO.
  38. NOTE: Install the special tools in the position shown in illustration.

    Install the special tools and special tools bolts.

    • Tighten to 18 Nm (159 lb-in).
      Fig 37: Locating Special Tool Mounting Bolts
      G08867150Courtesy of FORD MOTOR CO.
  39. Turn the special tool bolt approximately 20 turns to separate the clutch housing from the transmission case.
    Fig 38: Turning Special Tool Bolt
    G08867151Courtesy of FORD MOTOR CO.
  40. Lift the clutch housing off the transmission case.
    Fig 39: Lifting Off Clutch Housing From Transmission Case
    G08867152Courtesy of FORD MOTOR CO.
  41. Remove and discard the clutch housing input shaft bearing retainer bolts and remove clutch housing input shaft bearing retainer.
    Fig 40: Locating Clutch Housing Input Shaft Bearing Retainer Bolts
    G08867153Courtesy of FORD MOTOR CO.
  42. By lightly tapping, remove and discard the clutch housing input shaft bearing.
  43. Remove the differential.
    Fig 41: Locating Differential
    G08867154Courtesy of FORD MOTOR CO.
  44. Remove the park pawl actuation shaft assembly.
    Fig 42: Locating Park Pawl Actuation Shaft Assembly
    G08867155Courtesy of FORD MOTOR CO.
  45. Remove the park pawl rod and park pawl.
    Fig 43: Removing Park Pawl Rod And Park Pawl
    G08867156Courtesy of FORD MOTOR CO.
  46. Remove the large clock gears and clock gear pins.
    Fig 44: Removing Large Clock Gears And Clock Gear Pins
    G08867157Courtesy of FORD MOTOR CO.
  47. Remove the small clock gears and clock gear pins.
    Fig 45: Removing Small Clock Gears And Clock Gear Pins
    G08867158Courtesy of FORD MOTOR CO.
  48. Remove the magnet.
    Fig 46: Locating Magnet
    G08867159Courtesy of FORD MOTOR CO.
  49. Install the special tool on the transmission case and gear set assembly.
    Fig 47: Removing/Installing Special Tool
    G08867160Courtesy of FORD MOTOR CO.
  50. Turn the transmission case and gear set assembly over on the special tool.
    Fig 48: Turning Transmission Case And Gear Set Assembly
    G08867161Courtesy of FORD MOTOR CO.
  51. Remove the special tool from the transmission case.
    Fig 49: Removing Special Tool From Transmission Case
    G08867162Courtesy of FORD MOTOR CO.
  52. Remove and discard the 6 output shaft bearing retainer bolts.
    Fig 50: Removing Output Shaft Bearing Retainer Bolts
    G08867163Courtesy of FORD MOTOR CO.
  53. Lift the transmission case off the gearset assemblies.
    Fig 51: Lifting Transmission Case From Gear Set Assemblies
    G08867164Courtesy of FORD MOTOR CO.
  54. Remove the park plunger plug.
    Fig 52: Locating Park Plunger Plug
    G08867165Courtesy of FORD MOTOR CO.
  55. Remove the park plunger.
    Fig 53: Locating Park Plunger
    G08867166Courtesy of FORD MOTOR CO.
  56. Remove the oil spout.
    Fig 54: Locating Oil Spout
    G08867167Courtesy of FORD MOTOR CO.
  57. Remove the 4 shift fork rods.
    Fig 55: Removing Shift Fork Rods
    G08867168Courtesy of FORD MOTOR CO.
  58. Remove the 2 shift drums.
    Fig 56: Locating Shift Drums
    G08867169Courtesy of FORD MOTOR CO.
  59. Remove the shift forks and linkages.
    Fig 57: Locating Shift Forks And Linkages
    G08867170Courtesy of FORD MOTOR CO.
  60. Install the special tool.
    Fig 58: Installing Special Tool
    G08867171Courtesy of FORD MOTOR CO.
  61. Turn the gearset assembly over on its side.
    Fig 59: Turning Gear Set Assembly
    G08867172Courtesy of FORD MOTOR CO.
  62. Remove the special tool.
    Fig 60: Removing Special Tool
    G08867173Courtesy of FORD MOTOR CO.
  63. Remove output shaft 1 assembly by removing the special tool.
    Fig 61: Removing Output Shaft 1 Assembly Using Special Tool
    G08867174Courtesy of FORD MOTOR CO.
  64. Remove the input shaft assembly by removing the special tool.
    Fig 62: Removing Input Shaft Assembly Using Special Tool
    G08867175Courtesy of FORD MOTOR CO.
  65. Remove the special tool from output shaft 2 assembly.
    Fig 63: Removing Special Tool From Output Shaft 2 Assembly
    G08867176Courtesy of FORD MOTOR CO.
  66. Remove the hollow input shaft from the solid input shaft.
    Fig 64: Removing Hollow Input Shaft From Solid Input Shaft
    G08867177Courtesy of FORD MOTOR CO.
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