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Section 309 (Manual Transmission-IB5): Assembly: Transaxle: Assembly

WARNING: This page is about a different car, the 2003 Ford Focus. However, it is still accessible from the selected car via links, so may be relevant.
  1. Clean and check all parts carefully before reassembly.
    • Apply manual transmission fluid to all running surfaces.
  2. Using the special tool, install the output shaft roller bearing and bearing cone.
    1. Install the oil thrower.
    2. Drive in the roller bearing as far as stop.
      Fig 1: Installing Output Shaft Roller Bearing And Bearing Cone
      G01613341Courtesy of FORD MOTOR CO.
  3. Using the special tool, install the differential bearing cone.
    Fig 2: Installing Differential Bearing Cone
    G01613342Courtesy of FORD MOTOR CO.
  4. Install the selector rod with the locking plate.
    1. Install the shift selector interlock plate.
    2. Install the fifth and reverse gear selector rod.
      Fig 3: Installing Selector Rod With Locking Plate
      G01613343Courtesy of FORD MOTOR CO.
  5. Install the reverse idle gear.
    Fig 4: Installing Reverse Idle Gear
    G01613344Courtesy of FORD MOTOR CO.
  6. Install the differential and the permanent magnet.
    Fig 5: Installing Differential And Permanent Magnet
    G01613345Courtesy of FORD MOTOR CO.
  7. Install the fifth and reverse gear selector shaft and shift locking bush.
    1. Shift selector interlock plate
    2. Fifth and reverse gear selector shaft
      Fig 6: Installing Fifth And Reverse Gear Selector Shaft And Shift Locking Bush
      G01613346Courtesy of FORD MOTOR CO.
    8. NOTE: Installation position for the reverse gear idler.
  8. Install the reverse gear idler, the differential and the permanent magnet.
    1. Reverse gear idler
    2. Differential
    3. Permanent magnet
      Fig 7: Installing Reverse Gear Idler, Differential And Permanent Magnet
      G01613347Courtesy of FORD MOTOR CO.
  9. Prepare the input and the output shaft for installation.
    1. Engage the input shaft and the output shaft.
    2. Position the first and second gear selector fork.
    3. Position the third and fourth gear selector fork.
      Fig 8: Preparing Input And Output Shaft For Installation
      G01613348Courtesy of FORD MOTOR CO.
  10. Install the input shaft and the output shaft.
    • Install a rubber band to the selector shaft to aid assembly.
    • Insert the input shaft to a depth of approximately 50 mm and swivel it slightly to the side.
    • Insert the output shaft to the level of the input shaft and engage the gearwheels.
    • Position the input shaft and the output shaft.
      Fig 9: Installing Input Shaft And Output Shaft
      G01613349Courtesy of FORD MOTOR CO.
    11. NOTE: Install a new snap ring.
  11. Install the selector shaft guide sleeve.
    1. Push in the guide sleeve.
    2. Install the lower snap ring.
      Fig 10: Installing Selector Shaft Guide Sleeve
      G01613350Courtesy of FORD MOTOR CO.
    12. NOTE: Install a new snap ring.
  12. Install the selector shaft guide sleeve upper snap ring.
    1. Pull up the guide sleeve.
    2. Install the upper snap ring.
      Fig 11: Installing Selector Shaft Guide Sleeve Upper Snap Ring
      G01613351Courtesy of FORD MOTOR CO.
  13. Move the inner gearshift linkage to fifth gear.
    • Turn the selector shaft clockwise until the reverse and fifth gear passage is reached, then press downwards.
      Fig 12: Moving Inner Gearshift Linkage To Fifth Gear
      G01613352Courtesy of FORD MOTOR CO.
  14. Install the measuring shim and secure with a blow from a punch.
    1. Transaxle housing
    2. Measuring shim (3.8 mm thick)
    3. Bearing cone
      Fig 13: Installing Measuring Shim
      G01613353Courtesy of FORD MOTOR CO.
    15. NOTE: Thoroughly clean the mating face.
    Fig 14: Assembling Transaxle Housing
    G01613354Courtesy of FORD MOTOR CO.
  15. Using the special tool, assemble the transaxle housing.
  16. Install the special tools.
    • Remove the special tool 308-152.
      Fig 15: Installing Special Tool
      G01613355Courtesy of FORD MOTOR CO.
  17. Prepare the differential for measuring.
    • Turn the differential at least ten times to settle the bearings.
    • Install the special tools and "zero" the dial indicator.
      Fig 16: Preparing Differential For Measuring
      G01613356Courtesy of FORD MOTOR CO.
    18. NOTE: Carry out the previous steps three times and calculate the average measurement.
  18. Measure the differential end float.
    1. Using the special tools, raise the differential.
    2. Read off the measurement.
    • Example:
      • Measurement: 0.73 mm
      • Measurement: 0.74 mm
      • Measurement: 0.72 mm
      • Average = 0.73 mm + 0.74 mm + 0.72 mm / 3 = 0.73 mm.
    • The washer thickness to be determined should be rounded down to 0.05 mm and below, and rounded up from 0.06 mm and above.
    • The adjusting shims are available from 0.1 mm to 1.1 mm in steps of 0.1 mm.
      Fig 17: Measuring Differential End Float
      G01613357Courtesy of FORD MOTOR CO.
  19. Determine the adjusting shim to be installed (example).
    • Thickness of adjusting shim =
      • Measuring shims (3.80 mm) +
      • Average value (0.73 mm) +
      • Bearing preload (0.14 mm) -
      • Thickness of the Belleville washers (4.42 mm) =
      • 3.80 mm + 0.73 mm + 0.14 mm - 4.42 mm = 0.25 mm.
      • The thickness of the adjusting shim should be 0.25 mm, which is rounded down to 0.20 mm.
  20. Separate the transmission housing sections.
    • Remove the special tools.
      Fig 18: Separating Transmission Housing Sections
      G01613358Courtesy of FORD MOTOR CO.
  21. Remove the bearing cone and measuring shim.
    Fig 19: Removing Bearing Cone And Measuring Shim
    G01613359Courtesy of FORD MOTOR CO.
    22. NOTE: The inner diameters of the Belleville washers are touching.
  22. Install the adjusting shim determined and secure with a blow from a punch.
    1. Belleville washers.
    2. Appropriate adjusting shim.
    3. Install the bearing cone and secure it with a punch mark on the edge of the housing.
      Fig 20: Installing Adjusting Shim
      G01613360Courtesy of FORD MOTOR CO.
  23. Apply Sealant transaxle housing to the transaxle housing evenly.
    Fig 21: Applying Sealant Transaxle Housing To Transaxle Housing Evenly
    G01613361Courtesy of FORD MOTOR CO.
    24. NOTE: Tighten the stud connections to 33 Nm.
    Fig 22: Assembling Transaxle Housing
    G01613362Courtesy of FORD MOTOR CO.
  24. Assemble the transaxle housing and tighten the bolts evenly.
    25. NOTE: Use a wooden block.
    NOTE: Install new snap rings.
    Fig 23: Installing Input Shaft And Output Shaft Snap Rings
    G01613363Courtesy of FORD MOTOR CO.
  25. Install the input shaft and the output shaft snap rings.
    26. NOTE: Turn the snap rings so that they are located in the cut-outs in the gasket.
  26. Install the gasket.
    • Install the special tools.
      Fig 24: Installing Gasket
      G01613364Courtesy of FORD MOTOR CO.
    27. NOTE: Install new retaining bolts.
    Fig 25: Installing Fifth Gear Housing
    G01613365Courtesy of FORD MOTOR CO.
  27. Install the fifth gear housing.
    28. CAUTION: Remove the transaxle from the special tool 307-003 and carry out the following step on a press.
    NOTE: Install an anti twist stop for the selector rod.
    NOTE: The transaxle housing must not rest on the press table. Support the input shaft clutch splines on the press.
  28. Using the special tool and a press, install the fifth gear wheel onto the input shaft.
    • Install the transaxle to special tool 307-003.
      Fig 26: Installing Fifth Gear Wheel Onto Input Shaft
      G01613366Courtesy of FORD MOTOR CO.
    29. CAUTION: Select the new snap ring with a minimum of clearance.
  29. Using the special tool, install the fifth gear wheel snap ring.
    1. Install the snap ring onto the special tool.
    2. Install the special tool and push on the snap ring.
      Fig 27: Installing Fifth Gear Wheel Snap Ring
      G01613367Courtesy of FORD MOTOR CO.
    30. NOTE: Identification of gear synchronizer installation position.
  30. Assemble the fifth gear synchronizer unit.
    1. Gear wheel (fifth gear).
    2. Synchronizer ring.
    3. Gear synchronizer.
    4. Retaining plate.
      Fig 28: Assembling Fifth Gear Synchronizer Unit
      G01613368Courtesy of FORD MOTOR CO.
    31. NOTE: Install a new retaining bolt.
    NOTE: Install a new retaining ring.
  31. Install the fifth gear synchronizer unit with selector fork.
    • Install the securing bolt.
    • Install a new retaining ring.
      Fig 29: Installing Fifth Gear Synchronizer Unit With Selector Fork
      G01613369Courtesy of FORD MOTOR CO.
  32. Apply End cap sealer evenly to the end cap.
    Fig 30: Applying End Cap Sealer Evenly To End Cap
    G01613370Courtesy of FORD MOTOR CO.
  33. Install the fifth gear cover.
    Fig 31: Installing Fifth Gear Cover
    G01613371Courtesy of FORD MOTOR CO.
    34. NOTE: Only perform the installation in neutral.
    Fig 32: Identifying Installation Position For Selector Shaft Interlock
    G01613372Courtesy of FORD MOTOR CO.
  34. Installation position for selector shaft interlock.
    35. NOTE: Only perform the installation in neutral
  35. Install the selector interlock mechanisms.
    • Apply Universal sealant (Hylomar) to the thread.
      Fig 33: Installing Selector Interlock Mechanisms
      G01613373Courtesy of FORD MOTOR CO.
  36. Install the lever.
    • Install the gaiter.
      Fig 34: Installing Lever
      G01613374Courtesy of FORD MOTOR CO.
  37. Using the special tool, install the input shaft oil seal until it engages audibly.
    Fig 35: Installing Input Shaft Oil Seal
    G01613375Courtesy of FORD MOTOR CO.
  38. Engage fifth gear.
    • Turn the selector shaft clockwise as far as possible and press it in.
      Fig 36: Engaging Fifth Gear
      G01613376Courtesy of FORD MOTOR CO.
  39. Install the special tools.
    Fig 37: Installing Special Tools
    G01613377Courtesy of FORD MOTOR CO.
  40. Install the selector cable bracket.
    Fig 38: Installing Selector Cable Bracket
    G01613378Courtesy of FORD MOTOR CO.
    41. NOTE: Install a new snap ring.
  41. Install the selector lever.
    1. Install the snap ring.
    2. Install the protective cap.
      Fig 39: Installing Selector Lever
      G01613379Courtesy of FORD MOTOR CO.
  42. Install the shift cable cover.
    Fig 40: Installing Shift Cable Cover
    G01613380Courtesy of FORD MOTOR CO.
  43. Install the vehicle speed sensor (VSS).
    1. Connect the VSS.
    2. Install the retaining pin.
      Fig 41: Installing Vehicle Speed Sensor (VSS)
      G01613381Courtesy of FORD MOTOR CO.
  44. Install the input shaft oil seal and the clutch slave cylinder.
    1. Position the input shaft oil seal.
    2. Position the clutch slave cylinder.
    3. Tighten the bolts evenly.
      Fig 42: Installing Input Shaft Oil Seal And Clutch Slave Cylinder
      G01613382Courtesy of FORD MOTOR CO.
  45. Remove the transaxle from the stand.
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