FixVault
Home › Ford › 1990 › Festiva L › Repair and Diagnosis › Transmission › Manual Trans › Overhaul - 5-Speed › Transaxle Reassembly

Transaxle Reassembly

  1. Perform bearing preload adjustments. See DIFFERENTIAL BEARING PRELOAD  , MAINSHAFT BEARING PRELOAD  and INPUT SHAFT BEARING PRELOAD  under ADJUSTMENTS. Assemble case components. See CASE REASSEMBLY  under TRANSAXLE DISASSEMBLY.
  2. Install oil channel. Install oil baffle plate. Tighten to specification. See TORQUE SPECIFICATIONS  table at end of article. Install one interlock plug into plug bore. See Figure . Position plug between 1st-2nd and 5th-reverse shift rail bores. See Fig 1 . Ensure end of plug does not extend into 5th-reverse shift rail bore.
    Fig 1: Installing Interlock Plug
    G92E13957Courtesy of FORD MOTOR CO.
  3. Install interlock pin into hole near the end of 5th-reverse shift rail. Use grease to hold pin in position. Ensure all synchronizers are in Neutral position.
  4. Install 1st-2nd shift fork onto mainshaft assembly. If removed, install 5th gear shift fork onto shift rail. Install 5th gear shift rail assembly onto mainshaft.
  5. Mesh input shaft assembly and mainshaft assembly. Install as a unit. See Fig 2 . Use a small thin tool to push interlock plug back into it's bore while slightly raising and lowering 5th-reverse shift rail. The 5th-reverse shift rail is properly positioned when interlock plug no longer extends into 1st-2nd shift rail bore.
    Fig 2: Installing Shaft & Gear Assemblies
    G92F13958Courtesy of FORD MOTOR CO.
  6. Install 1st-2nd shift rail through shift fork and into shift rail bore. Detents in shift rail should face away from mainshaft. If 1st-2nd shift rail won't enter bore, slightly lift and lower 5th-reverse shift rail while pushing down on 1st-2nd shift rail.
  7. Install 3rd-4th shift fork and shift rail. Detents in 3rd-4th shift rail should be facing directly away from 5th-reverse shift shaft. Hold 3rd-4th relay arm in position while installing shift rail.
  8. Rest 3rd-4th gear shift rail on mating surface of clutch housing while slightly lifting and lowering 5th-reverse shift rail and pushing interlock plug back into its bore. The 5th-reverse shift rail is properly positioned when plug no longer extends into 3rd-4th shift rail bore. Pivot 3rd-4th shift rail into position and install in shift rail bore.
  9. Install roll pins into shift forks, relay arm and shift rail ends. All shift fork and 3rd-4th shift rail end roll pins are .87" (22 mm) in length. Roll pin for 5th-reverse shift rail end is .79" (20.0 mm) in length. Both roll pin types are .20" (5.0 mm) diameter.
  10. Install new "O" ring on reverse relay lever pivot pin and install through case and reverse relay lever. Install retaining pin into reverse lever pivot. Install reverse idler gear onto idler gear shaft so that idler gear sleeve faces roll pin hole in idler gear shaft.
  11. Raise reverse shift lever and install reverse idler gear and shaft assembly. Install detent plate under reverse shift lever. Tighten to specification. See TORQUE SPECIFICATIONS  .
  12. Install case magnet. Apply 1/16" (1.5 mm) bead of gasket eliminator on clutch housing mating surface. Ensure sealer encircles clutch housing bolt holes. Install transaxle case onto clutch housing. Tighten bolts to specification. See TORQUE SPECIFICATIONS  .
  13. Install detent springs and balls. Detent springs for transaxle case are .89" (22.6 mm) in length. Detent spring for clutch housing is 1.31" (33.3 mm) in length. Both springs are .28" (7.1 mm) diameter.
  14. Coat threads with pipe sealant and install detent plugs and back-up light switch. Install transaxle mount onto case. Tighten to specification. See TORQUE SPECIFICATIONS  . Ensure input shift shaft bushings are installed. Shift transaxle through all gears to ensure operation.
About FixVault