Manual Transmission: Assembly: Transaxle: Assembly

Apply lubricant throughout the assembly procedure. Lubricate all bearings, gears and synchronizers with the recommended transmission lubricant.
Attach the transmission to the special tool.
Apply sealer to the reverse gear idler shaft plate mating face. Install the reverse gear idler shaft.

Fig 1: Installing Reverse Gear Idler Shaft Plate
Courtesy of FORD MOTOR CO.

NOTE: If new output shaft bearings were installed, install new output shaft bearing cups. Always install new bearings and cups in a set.

NOTE: Use a heat gun on the case bearing cup area to aid installation.

Fig 2: Installing Output Shaft Bearing Cup In Case (Transmission Side)

Courtesy of FORD MOTOR CO.

Using the special tools, install the output shaft bearing cup in the case (transmission side).

NOTE: If new input shaft bearings were installed, install new input shaft bearing cups. Always install new bearings and cups in a set.

NOTE: Use a heat gun on the case bearing cup area to aid installation.

Fig 3: Installing Input Shaft Bearing Cup In Case (Transmission Side)

Courtesy of FORD MOTOR CO.

Using a suitable driver, install the input shaft bearing cup in the case (transmission side).

NOTE: If new differential bearings were installed, install new differential bearing cups. Always install new bearings and cups in a set.

NOTE: Use a heat gun on the case bearing cup area to aid installation.

Fig 4: Installing Differential Bearing Cup In Case (Transmission Side)

Courtesy of FORD MOTOR CO.

Using a suitable driver, install the differential bearing cup in the case (transmission side).

NOTE: If new input shaft bearings were installed, install new input shaft bearing cups. Always install new bearings and cups in a set.

NOTE: Use a heat gun on the case bearing cup area to aid installation.

Fig 5: Installing Input Shaft Bearing Cup In Case (Clutch Side)

Courtesy of FORD MOTOR CO.

Install a 1.00 mm (0.03 in) shim. Using a suitable driver, install the input shaft bearing cup in the case (clutch side).

NOTE: If new output shaft bearings were installed, install new output shaft bearing cups. Always install new bearings and cups in a set.

NOTE: Use a heat gun on the case bearing cup area to aid installation.

Fig 6: Installing Output Shaft Bearing Cup In Case (Clutch Side)

Courtesy of FORD MOTOR CO.

Install a 1.00 mm (0.03 in) shim. Using a suitable driver, install the output shaft bearing cup in the case (clutch side).

NOTE: If new differential bearings were installed, install new differential bearing cups. Always install new bearings and cups in a set.

NOTE: Use a heat gun on the case bearing cup area to aid installation.

Fig 7: Installing Differential Bearing Cup In Case (Clutch Side)

Courtesy of FORD MOTOR CO.

Install a 1.10 mm (0.04 in) shim. Using a suitable driver, install the differential bearing cup in the case (clutch side).
Engage the fourth gear synchronizer on the input shaft.

Fig 8: Engaging Fourth Gear Synchronizer On Input Shaft
Courtesy of FORD MOTOR CO.
Assemble the input and output shafts together and put them in the transaxle case as an assembly.

Fig 9: Installing Input And Output Shafts
Courtesy of FORD MOTOR CO.
Install the differential assembly.

Fig 10: Installing Differential Assembly
Courtesy of FORD MOTOR CO.

NOTE: Do not apply sealer at this time.

Fig 11: Installing Housing Case Bolts

Courtesy of FORD MOTOR CO.

Position the housing and install the 16 case bolts uniformly.
Using the special tool, rotate the input shaft to seat the bearings.

Fig 12: Rotating Input Shaft To Seat Bearings
Courtesy of FORD MOTOR CO.
Install the special tool to measure input shaft end play.
- Make sure the dial indicator is off center on the end of the input shaft.
- Zero the dial indicator.
  
  Fig 13: Measuring Input Shaft End Play
  Courtesy of FORD MOTOR CO.
Measure the input shaft end play.
1. Using a lever, lift up on the input shaft.
2. Observe and record the dial indicator reading.
  - Carry out the measurement three times and calculate the average measurement.
    Example: 0.22 mm + 0.23 mm + 0.21 mm divided by three = 0.22 mm.
    
    Fig 14: Measuring Input Shaft End Play
    Courtesy of FORD MOTOR CO.
Install the special tools to measure output shaft end play.
- Install the holding fixture to the transmission then install the dial indicator gauge.
- Position the special tool on fourth gear.
- Zero the dial indicator.
  
  Fig 15: Installing Special Tools
  Courtesy of FORD MOTOR CO.
Measure the output shaft end play.
- Using a lever, lift up on the output shaft. Note the resulting measurement, for example, 0.32 mm.
- Carry out the measurement three times and calculate the average measurement. Observe and record the dial indicator reading.
  Example: 0.32 mm (0.01 in) + 0.34 mm + 0.33 mm divided by three = 0.33 mm.
  
  Fig 16: Measuring Output Shaft End Play
  Courtesy of FORD MOTOR CO.
Install the special tools. Prepare the differential for measuring.
- Using the special tools, rotate the output shaft and at the same time press down.
- Set up the special tool and set it to zero.
  Carry out the measurement three times and calculate the average measurement.
  
  Fig 17: Rotating Output Shaft
  Courtesy of FORD MOTOR CO.
Using the special tools, measure the differential end play.
- Observe and record the dial indicator reading.
  
  Fig 18: Measuring Differential End Play
  Courtesy of FORD MOTOR CO.
Using the measurements, select the appropriate shims for the differential, input shaft and the output shaft. For additional information, refer to SPECIFICATIONS .

NOTE: Use a heat gun on the case bearing cup area to aid removal.

Remove the output shaft bearing input shaft bearing cup, the differential bearing cup and the shims (clutch side).

NOTE: Use a heat gun on the case bearing cup area to aid installation.

Install the appropriate shims and the bearing cups.
1. Install the appropriate shims.
2. Install the bearing cups.
  
  Fig 19: Installing Shims And Bearing Cups
  Courtesy of FORD MOTOR CO.
Apply a light coat of petroleum jelly, then install the lower thrust washer.
- Tab on the washer faces downward.
  
  Fig 20: Installing Lower Thrust Washer
  Courtesy of FORD MOTOR CO.
Install the reverse idler gear and the upper thrust washer. Do not install the bearing at this time.
- Install the gear with the oil grooves facing downward.
  
  Fig 21: Installing Reverse Idler Gear And Upper Thrust Washer
  Courtesy of FORD MOTOR CO.

NOTE: Position the fourth gear selector ring into the neutral position.

Fig 22: Positioning Fourth Gear Selector Ring Into Neutral Position

Courtesy of FORD MOTOR CO.

Push the reverse idler gear away from the output shaft bearing cup. Install the input shaft and the output shaft as an assembly. Position both shafts into the bearing cups and align with the reverse idler gear.
Install the reverse idler gear needle bearing.

Fig 23: Installing Reverse Idler Gear Needle Bearing
Courtesy of FORD MOTOR CO.
Install the reverse idler gear retainer.

Fig 24: Installing Reverse Idler Gear Retainer
Courtesy of FORD MOTOR CO.
Install the shift forks.
1. Install the fifth/reverse gear selector fork and position it to the side.
2. Install the third/fourth gear selector fork.
3. Install the first/second gear selector fork.
  
  Fig 25: Installing First/Second Gear Selector Fork
  Courtesy of FORD MOTOR CO.
Install the shift rails.
- When installed, the selector rods are the same height.
  
  Fig 26: Installing Shift Rails
  Courtesy of FORD MOTOR CO.
Install the differential assembly.

Fig 27: Installing Differential Assembly
Courtesy of FORD MOTOR CO.
Install the magnetic disc.

Fig 28: Installing Magnetic Disc
Courtesy of FORD MOTOR CO.
Install the reverse idler gear retainer bolts.

Fig 29: Installing Reverse Idler Gear Retainer Bolts
Courtesy of FORD MOTOR CO.
Clean the mating surfaces of the selector mechanism and the transaxle case. Apply a bead of sealant to the sealing surface of the transaxle case. Install the selector mechanism.

Fig 30: Installing Selector Mechanism
Courtesy of FORD MOTOR CO.
Clean the mating surfaces of the transaxle main case. Apply a bead of sealant to the sealing surface on the transaxle case. Install the transaxle housing.

Fig 31: Applying Bead Of Sealant To Sealing Surface On Transaxle Case
Courtesy of FORD MOTOR CO.

NOTE: The transaxle housing must not be turned over to tighten the bolts.

NOTE: Do not wait longer than 10 minutes to tighten the bolts due to the rapid cure time of the sealant.

Fig 32: Installing Transaxle Housing Bolts

Courtesy of FORD MOTOR CO.

Install the 16 transaxle housing bolts.
Install the vehicle speed sensor (VSS).

Fig 33: Installing Vehicle Speed Sensor (VSS)
Courtesy of FORD MOTOR CO.
Using the special tools, install new differential oil seals.

Fig 34: Installing Differential Oil Seals
Courtesy of FORD MOTOR CO.

CAUTION: If brake fluid is split on the paintwork, the affected area must be immediately washed down with cold water.

CAUTION: Using suitable adhesive tape, cover the input shaft splines to prevent damage to the input shaft oil seal.

CAUTION: Do not apply grease on any area of the clutch slave cylinder.

NOTE: Install a new clutch slave cylinder.

Install the slave cylinder with sealer and install a new slave cylinder with a new seal.
- Make sure the seals are correctly installed or it may cause starter failure.
  
  Fig 35: Installing Slave Cylinder With New Seal
  Courtesy of FORD MOTOR CO.
Coat the input shaft splines with a thin layer of grease.