Manual Transmission: Disassembly: Transaxle: Disassembly

WARNING: Wear protective eyewear whenever using compressed air.

Clean the transaxle exterior with solvent, and dry with compressed air.

WARNING: Wear protective eyewear whenever using compressed air.

Clean all parts removed with solvent and dry with compressed air.
Remove and discard the clutch slave cylinder.

Fig 1: Locating Clutch Release Bearing
Courtesy of FORD MOTOR CO.
Install the special tool.

Fig 2: Identifying Special Tool
Courtesy of FORD MOTOR CO.

NOTE: Position the selector in the NEUTRAL position.

Fig 3: Locating Gearshift Mechanism Bolts

G04653387

Courtesy of FORD MOTOR CO.

Remove the gearshift mechanism.
Remove the vehicle speed sensor (VSS).

Fig 4: Locating Vehicle Speed Sensor (VSS) Bolt
Courtesy of FORD MOTOR CO.

NOTE: Rotate the transaxle with the input shaft pointing upward.

Fig 5: Locating Transaxle Housing Bolts

G04653389

Courtesy of FORD MOTOR CO.

Remove the 16 transaxle housing bolts.

CAUTION: Take care not to damage the transaxle housing.

Fig 6: Prying Transaxle Housing From Transaxle Main Case

G04653390

Courtesy of FORD MOTOR CO.

Carefully pry the transaxle housing from the transaxle main case.
Remove the transaxle housing.

Fig 7: Removing Transaxle Housing
Courtesy of FORD MOTOR CO.
Remove the differential.

Fig 8: Identifying Differential
Courtesy of FORD MOTOR CO.
Remove and clean the magnetic disc.

Fig 9: Locating Magnetic Disc
Courtesy of FORD MOTOR CO.
Remove the shift rails and the 1st and 2nd gear shift fork.

Fig 10: Locating Shift Rails And 1st And 2nd Gear Shift Fork
Courtesy of FORD MOTOR CO.
Remove the shift forks.
1. Move the 5th and reverse gear selector fork to the side.
2. Rotate the 3rd and 4th gear selector fork and remove.
- Remove the 5th and reverse gear selector fork.
  
  Fig 11: Locating 5th And Reverse Gear Selector Fork
  Courtesy of FORD MOTOR CO.
Remove the 2 reverse idler gear bolts.

Fig 12: Locating Reverse Idler Gear Bolts
Courtesy of FORD MOTOR CO.
Remove the input and the output shaft.
- Lift out the input and the output shaft from transaxle housing together.
  
  Fig 13: Locating Input And Output Shaft
  Courtesy of FORD MOTOR CO.
Remove the reverse idler gear retainer, then lift out the reverse idler gear.

Fig 14: Locating Reverse Idler Gear Retainer
Courtesy of FORD MOTOR CO.
Remove the following:
1. Upper thrust washer.
2. Reverse idler gear.
3. Reverse idler gear bearing.
4. Lower thrust washer.
  
  Fig 15: Identifying Thrust Washer And Idler Gear Bearing
  Courtesy of FORD MOTOR CO.
Remove and discard the halfshaft oil seals.

Fig 16: Locating Halfshaft Oil Seals
Courtesy of FORD MOTOR CO.

Fig 17: Locating Halfshaft Oil Seals
Courtesy of FORD MOTOR CO.
Using a heat gun, heat the case bearing cup area. Using the special tool, remove the differential bearing race from the case (clutch side).

Fig 18: Removing Differential Bearing Race From Case
Courtesy of FORD MOTOR CO.
Using a heat gun, heat the case bearing cup area. Using the special tool, remove the output shaft bearing race (clutch side).

Fig 19: Removing Output Shaft Bearing Race
Courtesy of FORD MOTOR CO.
Using a heat gun, heat the case bearing cup area. Using the special tool, remove the input shaft bearing race (clutch side).

Fig 20: Removing Input Shaft Bearing Race
Courtesy of FORD MOTOR CO.
Remove the shims.

Fig 21: Locating Shims
Courtesy of FORD MOTOR CO.

Fig 22: Locating Shims
Courtesy of FORD MOTOR CO.
Using a heat gun, heat the case bearing area. Using the special tool, remove the input shaft bearing race from the case (transmission side).

Fig 23: Removing Input Shaft Bearing Race From Case
Courtesy of FORD MOTOR CO.
Using a heat gun, heat the case bearing area. Using the special tool, remove the output shaft bearing race from the case (transmission side).

Fig 24: Removing Output Shaft Bearing Race From Case
Courtesy of FORD MOTOR CO.
Using a heat gun, heat the case bearing area. Using the special tool, remove the differential bearing race from the case (transmission side).

Fig 25: Removing Differential Bearing Race From Case
Courtesy of FORD MOTOR CO.

NOTE: Only remove the reverse gear idler shaft if there is evidence of damage or leaks.

Fig 26: Locating Reverse Gear Idler Shaft Cover

G04653410

Courtesy of FORD MOTOR CO.

Remove the reverse gear idler shaft cover.

NOTE: Only remove the reverse gear idler shaft if there is evidence of damage or leaks.

Fig 27: Removing Reverse Gear Idler Shaft

G04653411

Courtesy of FORD MOTOR CO.

Using a brass drift, remove the reverse gear idler shaft.