Transaxle Reassembly
- Using seal installer, install differential oil seals. Using seal replacer and driver, install input shaft seal. Adjust bearing preloads and install selected shims, bearing races and related parts. See INPUT & OUTPUT SHAFT BEARING PRELOAD
and DIFFERENTIAL BEARING PRELOAD
.
- Using pilot bearing installer, install shift shaft seal. Install shift shaft and selector arm. Install NEW selector arm pin. Ensure shift shaft boot drain hole faces down. Install input shift shaft selector plate arm bolt and tighten to specification. See TORQUE SPECIFICATIONS
.
- Install control selector plate and reverse idler gear spacer. Tighten bolts to specification. Install differential. Assemble 3rd-4th shift fork and main shift shaft, input and output shaft as a single unit. Install complete assembly into clutch housing case. Keep assembly in vertical position during installation.
- Install shift fork selector lever onto selector lever arm and support. Install NEW "O" ring onto shift shaft lever. See Figure
. Install shift shaft lever through case and shift fork selector lever. Align shift shaft lever shaft and case holes. Install NEW roll pin through clutch housing into shift shaft lever.
- Position 5th-reverse shift gate onto clutch housing. Align holes and install shift gate bolt. Install reverse idler gear, bushing and reverse idler gear shaft. Install magnet. Install NEW "O" ring onto reverse lever shaft. Install reverse lever assembly and partially install shaft. Install steel ball and spring into reverse lever shaft.
- Using a small screwdriver, compress spring into shaft. Align holes and install NEW roll pin. Lightly coat reverse lever shaft plug with sealant. Install and stake plug. See Figure
. Install NEW vent into case. Install oil passage and tighten to specification. Align reverse idler shaft screw hole with alignment mark (if equipped) or case dowel. See Fig 1
.
- Place transaxle case onto clutch housing. Install transaxle case bolts and transaxle case-to-clutch housing retainer. Tighten bolts to specification. Install park/neutral switch and back-up light switch, using NEW copper washers. Tighten to specification. Install vehicle speed sensor to case.
- Install shift rail rear pin. Tighten to specification. Install reverse idle shaft detent ball, spring and lock bolt. Tighten to specification. See TORQUE SPECIFICATIONS
. Install ball, shift interlock spring and detent bolt into transaxle case. Install two Transaxle Plugs (T87C-7025-C) to prevent side gears from being displaced during installation procedures.
- Install 5th gear onto output shaft. Install gear sleeve, 5th gear and synchronize ring onto input shaft. Install 5th gear synchronizer assembly, shift fork and synchronizer hub together onto input shaft. Align 5th-reverse shift fork to shift shaft and install NEW roll pin.
- Install output reverse synchronizer gear onto output shaft. Install synchronizer ring and input reverse synchronizer gear and spacer onto input shaft. Loosely install NEW input and output shaft lock nuts. Lock input shaft with Input Shaft Holder (T88C-7025-GH).
- Tighten nuts to specification. See TORQUE SPECIFICATIONS
. Stake shaft lock nuts. Remove input shaft holder. Apply continuous bead of sealant to transaxle case. Install rear cover and tighten bolts to specification.
Courtesy of FORD MOTOR CO.