Manual Transmission: Disassembly: Transaxle: Disassembly

Clean the transaxle exterior with solvent and dry with 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

GF0040113

Courtesy of FORD MOTOR CO.

Install the special tool.

Fig 2: Identifying Special Tool

GF0040114

Courtesy of FORD MOTOR CO.

NOTE: Position the selector in the NEUTRAL position.

Remove the 6 gearshift mechanism bolts and the gearshift mechanism.

Fig 3: Locating Gearshift Mechanism Bolts

GF0040115

Courtesy of FORD MOTOR CO.

Remove the vehicle speed sensor (VSS).

Fig 4: Locating Vehicle Speed Sensor (VSS) Bolt

GF0040116

Courtesy of FORD MOTOR CO.

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

Remove the 16 transaxle housing bolts.

Fig 5: Locating Transaxle Housing Bolts

GF0040117

Courtesy of FORD MOTOR CO.

CAUTION: Take care not to damage the transaxle housing.

Carefully pry the transaxle housing from the transaxle main case.

Fig 6: Prying Transaxle Housing From Transaxle Main Case

GF0040118

Courtesy of FORD MOTOR CO.

Remove the transaxle housing.

Fig 7: Removing Transaxle Housing

GF0040119

Courtesy of FORD MOTOR CO.

Remove the differential assembly.

Fig 8: Identifying Differential

GF0040120

Courtesy of FORD MOTOR CO.

Remove and clean the magnetic disc.

Fig 9: Locating Magnetic Disc

GF0040121

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

GF0040122

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, then remove the 5th and reverse gear selector fork.

Fig 11: Locating 5th And Reverse Gear Selector Fork

GF0040123

Courtesy of FORD MOTOR CO.

Remove the 2 reverse idler gear bolts.

Fig 12: Locating Reverse Idler Gear Bolts

GF0040124

Courtesy of FORD MOTOR CO.

Lift out the input and the output shaft from transaxle housing together.

Fig 13: Locating Input And Output Shaft

GF0040125

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

GF0040126

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

GF0040127

Courtesy of FORD MOTOR CO.

Remove and discard the halfshaft oil seals.

Fig 16: Locating Halfshaft Oil Seals

GF0040128

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 17: Removing Differential Bearing Race From Case

GF0040129

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 18: Removing Output Shaft Bearing Race

GF0040130

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 19: Removing Input Shaft Bearing Race

GF0040131

Courtesy of FORD MOTOR CO.

Remove the shims.

Fig 20: Locating Shims

GF0040132

Courtesy of FORD MOTOR CO.

Fig 21: Locating Shims

GF0040133

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 22: Removing Input Shaft Bearing Race From Case

GF0040134

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 23: Removing Output Shaft Bearing Race From Case

GF0040135

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 24: Removing Differential Bearing Race From Case

GF0040136

Courtesy of FORD MOTOR CO.

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

Remove the 3 reverse gear idler shaft cover bolts and the reverse gear idler shaft cover.

Fig 25: Locating Reverse Gear Idler Shaft Cover

GF0040137

Courtesy of FORD MOTOR CO.

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

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

Fig 26: Removing Reverse Gear Idler Shaft

GF0040138

Courtesy of FORD MOTOR CO.