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Home >> Mercury >> 2002 >> Cougar 2.5 L, Automatic >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transaxle/Transmission >> Disassembly And Assembly Of Subassemblies >> Transaxle Case >> Disassembly

Transaxle Case: Disassembly

  1. Remove and discard the final drive lube tube.
    Fig 1: Removing And Discard Final Drive Lube Tube
    G02198617Courtesy of FORD MOTOR CO.
  2. Using the special tool, remove and discard the final drive lube tube seal.
    Fig 2: Removing And Discard Final Drive Lube Tube Seal
    G02198618Courtesy of FORD MOTOR CO.
  3. Remove the parking pawl ratcheting spring.
    Fig 3: Removing Parking Pawl Ratcheting Spring
    G02198619Courtesy of FORD MOTOR CO.
  4. Remove the manual control lever outer assembly.
    Fig 4: Removing Manual Control Lever Outer Assembly
    G02198620Courtesy of FORD MOTOR CO.
  5. Remove the manual control lever shaft assembly.
    Fig 5: Removing Manual Control Lever Shaft Assembly
    G02198621Courtesy of FORD MOTOR CO.
  6. Remove the parking pawl shaft retainer and bolt.
    Fig 6: Removing Parking Pawl Shaft Retainer And Bolt
    G02198622Courtesy of FORD MOTOR CO.
  7. Remove the parking pawl shaft.
    Fig 7: Removing Parking Pawl Shaft
    G02198623Courtesy of FORD MOTOR CO.
  8. Remove the parking pawl assembly.
    1. Remove the parking pawl.
    2. Remove the parking pawl return spring.
      Fig 8: Removing Parking Pawl Assembly
      G02198624Courtesy of FORD MOTOR CO.
    9. CAUTION: Do not damage the transaxle case bore during seal removal.
    Fig 9: Removing And Discard Manual Control Lever Seal
    G02198625Courtesy of FORD MOTOR CO.
  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 (Manual Valve Link)
    G02198626Courtesy of FORD MOTOR CO.
    11. CAUTION: Do not damage the transaxle case sealing surface.
    Fig 11: Removing And Discard Manual Valve Detent Lever Shaft Retaining Pin
    G02198627Courtesy of FORD MOTOR CO.
  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: Removing Manual Valve Detent Lever Shaft Retaining Pin
    G02198628Courtesy of FORD MOTOR CO.
  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: Removing Manual Valve Detent Lever And Shaft Assembly
      G02198629Courtesy of FORD MOTOR CO.
    14. CAUTION: Do not damage the seal bore in the case during seal removal.
    Fig 14: Removing And Discard Manual Control Seal
    G02198630Courtesy of FORD MOTOR CO.
  14. Remove and discard the manual control seal.
  15. If a new case is being installed, remove the line pressure port plug.
    Fig 15: Removing Line Pressure Port Plug
    G02198631Courtesy of FORD MOTOR CO.
  16. If a new case is being installed, remove and discard the cooler tube fitting.
    Fig 16: Removing And Discard Cooler Tube Fitting
    G02198632Courtesy of FORD MOTOR CO.
    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 was installed previously and a second installation is required, a new transaxle case must be installed.
  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.
    3. Remove the bearing.
      Fig 17: Removing No. 18 Driven Sprocket Bearing Assembly From Transaxle Case
      G02198633Courtesy of FORD MOTOR CO.
  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
      G02198634Courtesy of FORD MOTOR CO.
    19. WARNING: In order to avoid injury, eye protection should be worn when cleaning components with compressed air. Failure to follow these instructions can 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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