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Home >> Mercury >> 2001 >> Cougar Base, 2.5 L, Automatic >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transaxle >> Disassembly And Assembly Of Subassemblies >> Transaxle Case >> Disassembly

Transaxle Case: Disassembly

  1. Remove and discard the final drive lube tube.
    Fig 1: Removing Final Drive Lube Tube
    G02164656
  2. Using the special tool, remove and discard the final drive lube tube seal.
    Fig 2: Removing Final Drive Lube Tube Seal
    G02164657
  3. Remove the parking pawl ratcheting spring.
    Fig 3: Removing Parking Pawl Ratcheting Spring
    G02164658
  4. Remove the manual control lever outer assembly.
    Fig 4: Removing Manual Control Lever Outer Assembly
    G02164659
  5. Remove the manual control lever shaft assembly.
    Fig 5: Removing Manual Control Lever Shaft Assembly
    G02164660
  6. Remove the parking pawl shaft retainer and bolt.
    Fig 6: Removing Parking Pawl Shaft Retainer & Bolt
    G02164661
  7. Remove the parking pawl shaft.
    Fig 7: Removing Parking Pawl Shaft
    G02164662
  8. Remove the parking pawl assembly.
    1. Remove the parking pawl.
    2. Remove the parking pawl return spring.
    Fig 8: Removing Parking Pawl Assembly
    G02164663
    9. CAUTION: Do not damage the transaxle case bore during seal removal.
    Fig 9: Removing Manual Control Lever Seal
    G02164664
  9. Remove and discard the manual control lever seal.
  10. Remove the manual valve actuator rod (manual valve link).
    Fig 10: Removing Manual Valve Actuator Rod
    G02164665
    11. CAUTION: Do not damage the transaxle case sealing surface.
    Fig 11: Removing Manual Valve Detent Lever Shaft Retaining Pin
    G02164666
  11. Remove and discard the manual valve detent lever shaft retaining pin.
    12. CAUTION: Do not damage the transaxle case sealing surface.
    NOTE: There are two retaining pins, one on either side of the manual valve detent lever.
    Fig 12: Identifying Manual Valve Detent Lever Shaft Retaining Pin
    G02164667
  12. Remove the manual valve detent lever shaft retaining pin.
  13. Remove the manual valve detent lever and shaft assembly.
    1. Pull the manual valve detent lever and manual valve detent lever shaft from the transaxle case.
    2. Lift the manual valve detent lever from the transaxle case.
    Fig 13: Identifying Manual Valve Detent Lever & Shaft Assembly
    G02164668
    14. CAUTION: Do not damage the seal bore in the case during seal removal.
    Fig 14: Identifying Manual Control Seal
    G02164669
  14. Remove and discard the manual control seal.
  15. If the case is being replaced, then remove the line pressure port plug.
    Fig 15: Removing Line Pressure Port Plug
    G02164670
  16. If the case is being replaced, then remove and discard the cooler tube fitting.
    Fig 16: Removing & Discarding Cooler Tube Fitting
    G02164671
    17. NOTE: A new driven sprocket bearing No. 18 can be installed once before an installation of the transaxle case becomes necessary. If a new No. 18 driven sprocket bearing has been installed previously and requires a second installation a new transaxle case must be installed.
    Fig 17: Installing Special Tool Into Transaxle
    G02164672
  17. As necessary, remove the No. 18 driven sprocket bearing assembly from transaxle case.
    1. Install the special tool into the transaxle.
    2. Position the special tool.
  18. Using the special tools, remove the No. 18 driven sprocket bearing assembly.
    1. Position the special tool.
    2. Position the special tool.
    3. Remove the No. 18 driven sprocket bearing.
    Fig 18: Removing No. 18 Driven Sprocket Bearing Assembly
    G02164673
    19. WARNING: In order to avoid injury, eye protection should be worn when cleaning components with compressed air. Failure to follow these instructions may result in personal injury.
  19. Clean all components with a suitable solvent and use moisture-free compressed air to dry all parts and clean fluid passages. Check the following before assembling:
    • final drive lubrication tube for damage
    • manual control linkage for damage or wear
    • case mating surfaces for nicks or deformation
    • bearing wear
    • support area wear
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