Transaxle Disassembly: Transaxle

1. Mount transaxle in holding fixture. Remove drain plug, and drain any remaining transaxle fluid. Position transaxle with rear cover facing upward. Remove rear cover bolts. Loosen rear cover gasket seal with a plastic mallet and remove rear cover. See Fig 1 .
2. Shift transaxle to 1st gear. Use Torque Adapter (T88C-7025-GH) to lock up input shaft. Uncrimp tabs, and remove and discard input and output shaft lock nuts. Remove torque adapter from input shaft. Remove reverse synchronizer spacer, blocking ring retainer and blocking ring.
3. Using punch, remove and discard shift fork roll pin. Remove shift fork and synchronizer assembly. Remove synchronizer ring, 5th gear and 5th gear sleeve from input shaft. Remove output shaft 5th gear.
4. Remove lock bolt and washer, guide bolt and washer, back-up light switch and park/neutral switch from side of transaxle case. See Fig 1 . Remove transaxle case bolts. Note length and location of bolts for reassembly reference. Tap transaxle case lightly with a plastic hammer to loosen gasket seal, and remove case.
5. Remove magnet from case. Remove reverse idler shaft and gear. Remove and discard roll pin from shift lever shaft. Remove shift lever shaft and shift fork selector lever. Remove shift lever shaft "O" ring. Remove shift gate bolt and shift gate. Insert pin punch through roll pin hole of 5th gear shift shaft, and rotate and pull upward to remove.
6. Remove shift control rod and selector lever. Shift into 2nd and 4th gears. Place a shop towel over shift fork shaft and remove detent ball and shift fork shaft assembly. Remove input shaft, output shaft and shift fork from case as an assembly. Retrieve steel ball from clutch housing. Separate shift fork assembly from synchronizer sleeves.
NOTE: Remove case components as necessary for repair. Label bearing races and shims for reassembly reference.
7. Remove differential. Using slide hammer and bearing race puller, remove input shaft bearing race from clutch housing. Using puller, remove input shaft oil seal.
8. From transaxle case, remove input shaft bearing race along with adjustment shim(s). Remove input shaft oil seal. Remove output shaft bearing race, adjustment shim(s), diaphragm spring and funnel.
9. Remove output shaft bearing cup and 5th shaft funnel. Remove control selector plate and spacer. Remove shift control shaft selector lever bolt and remove shift control shaft selector lever. Drive roll pin from selector mounted on control shift shaft. Remove shift control shaft assembly. Use blind hole puller and remove shifter shaft seal. Remove 2 attaching bolts and remove vent tube from case. Remove vehicle speed sensor.
10. Using bearing remover and slide hammer, remove differential bearing cups. Remove and discard reverse lever roll pin. Remove reverse lever shaft and reverse lever. Remove park/neutral switch and gasket. Remove differential oil seals. Remove input and output shaft bearing races.

Fig 1: Exploded View Of Clutch Housing & Transaxle Case Components

Courtesy of FORD MOTOR CO.