Transaxle Disassembly: Notes

1. Place transaxle in Neutral position. Remove drain plug from transaxle case. Drain transaxle fluid. Set transaxle into a bench mounting fixture. Remove transaxle mount from case. Remove 1st-2nd detent plug, spring and ball. If necessary, use magnet to remove ball and/or spring. See Fig 1 .
2. Remove 5th-Reverse detent plug, spring and ball. Remove back-up light switch. Remove transaxle case bolts. Rotate transaxle so input shaft faces downward. Separate transaxle case from clutch housing. If necessary, tap case with plastic-tipped hammer.
3. Remove and label input and mainshaft adjustment shims for reassembly reference. It may be necessary to remove bearing outer races from transaxle case bores to obtain adjustment shims. Label shims and races for reassembly reference.
4. Remove case magnet. Remove reverse shift lever detent plate from below reverse shift lever pivot. Remove reverse idler gear and shaft. Remove retaining pin from reverse shift lever pivot. Remove pivot pin and reverse shift lever.
5. Remove 3rd-4th detent plug, spring and ball. Each shift rail has 3 detent positions. Ensure all shift rails are in Neutral (center) detent position. Using a roll pin punch and hammer, remove roll pins from the 3 shift forks and 3rd-4th relay lever on shift rail below 3rd-4th shift fork.
6. Using roll pin punch and hammer, remove 3rd-4th shift rail roll pin. Raise and lower 5th-reverse shift shaft slightly while pulling upward on 3rd-4th shift rail. When interlocks are aligned, 3rd-4th shift rail will slide out of case, relay lever and shift fork. Remove 3rd-4th relay lever and shift fork from case.
7. Using a magnet, remove one interlock plug from 3rd-4th detent bore in case. Raise and lower 5th-reverse shift shaft slightly while pulling upward on 1st-2nd shift rail. When interlocks are aligned, 1st-2nd shift rail will slide out of case and shift fork.
8. Remove input shaft, mainshaft and 5th-reverse shift rail assemblies as a unit. Use care not to lose interlock pin in end of 5th-reverse shift rail. Remove 2nd interlock plug from 3rd-4th detent bore. See CLEANING & INSPECTION  .

Fig 1: Disassembling 5-Speed Transaxle Cases & Main Components

Courtesy of FORD MOTOR CO.