FixVault
Home › Ford › 2009 › Escape Base, 2.5 7, AWD, Standard › Repair and Diagnosis › Transmission › Manual Trans › Manual Transmission › Disassembly And Assembly › Transaxle › Material

Disassembly And Assembly: Transaxle: Material

MATERIAL SPECIFICATIONS

Item Specification
Silicone Gasket and Sealant TA-30 WSE-M4G323-A4
Fig 1: Exploded View Of Clutch Housing
G06098318Courtesy of FORD MOTOR CO.
PART NUMBER DESCRIPTION

Item Part Number Description
1 7F096 Clutch housing
2 7048 Input shaft oil seal
3 1S177 RH intermediate shaft oil seal
4 - Funnel
5 7065 Mainshaft bearing
6 7A284 Mainshaft bearing retainer
7 99784 Mainshaft bearing retainer bolt
8 - Differential side bearing outer race
9 - Differential assembly
10 - Mainshaft assembly
11 - Input shaft assembly
12 - Reverse gear idler shaft assembly
13 7C114 1st/2nd gear shift fork
14 7328 1st/2nd gear shift rod
15 0414 1st/2nd gear shift fork roll pin
16 7K130 1st/2nd gear shift finger
17 0414 1st/2nd gear shift finger roll pin
18 - 1st/2nd gear check sleeve
19 7K131 3rd/4th gear shift finger
20 7230 3rd/4th gear shift fork
21 7326 3rd/4th gear shift rod
22 4097 Circlips (2 required)
23 0414 3rd/4th gear shift finger roll pin
24 - 3rd/4th gear shift roll pin
25 7D105 Interlock pins (2 required)
26 7K001 5th/reverse gear bracket
27 7L044 5th/reverse gear shift rod
28 4097 Circlips (2 required)
29 7F470 5th gear shift fork
30 0414 5th gear shift roll pin
31 7L063 Reverse gear shift fork
32 7B112 Reverse gear shift fork rod
33 0414 Shifter cap
34 - Reverse lever bracket
35 - Reverse lever bracket bolt (2 required)
36 7L027 Magnet
37 1S177 LH halfshaft oil seal
38 6K277 Plug
39 3C362 Differential side bearing adjustment shim
40 - Differential side bearing outer race
41 7L172 Mainshaft adjustment shim
42 - Mainshaft snap ring
43 7013 Input shaft adjustment shim
44 - Reverse idler gear adjustment shim
45 7L276 Oil gutter
46 7L276 Baffle plate
47 7005 Transaxle case
48 - Bore plug
49 99784 Transaxle case-to-clutch housing bolts (20 required)
50 7A082 Check balls (3 required)
51 - 5th/Reverse gear shift check sleeve
52 7A082 Spring (yellow)
53 7A082 Spring (blue)
54 7A082 Spring (white)
55 99784 Check plug (internal hex)
56 99784 Check plugs (external hex) (2 required)
57 7288 O-ring seal
58 7F116 Shift assembly
59 99784 Shift assembly bolt (4 required)
60 - Stopper bolt
61 - Shift check bolt
62 7034 Breather
63 15520 Reverse switch
64 - Fill plug
65 3972 Washers
66 7E380 Fluid level check
67 - Drain plug
68 - Plug
NOTE: Assembly should only be carried out in a clean environment or damage to the transaxle may occur.
NOTE: Be careful not to scratch the sliding face or mating faces or damage to the transaxle may occur.
NOTE: Visually inspect all parts for any damage, deformation or abnormal wear. Install new parts only if unsuitable or damage to the transaxle may occur.
NOTE: Do not work on the transaxle with cotton gloves. Cotton threads could become dislodged and damage to the transaxle may occur.
NOTE: Install all new retaining pins, oil seals, and bearings or damage to the transaxle may occur.
NOTE: Make sure to clean the old sealant from the mating threads of any sealed bolt or damage to the transaxle may occur.
  1. Using the Oil Seal Installer with the Adapter Handle, install a new input shaft oil seal.
    Fig 2: Installing Input Shaft Oil Seal
    G06098319Courtesy of FORD MOTOR CO.
  2. Using the Output Shaft Seal Installer, install a new RH intermediate shaft oil seal.
    Fig 3: Installing RH Intermediate Shaft Oil Seal
    G06098320Courtesy of FORD MOTOR CO.
  3. Install the funnel.
  4. Install the mainshaft bearing.
  5. Install the mainshaft bearing retainer and bolt.
    • Tighten to 7 Nm (62 lb-in).
    6. NOTE: Do not exceed 120°C (248°F) or damage to the clutch housing may occur.
  6. Heat the clutch housing to 100°C (212°F) and install a new differential side bearing outer race.
  7. Install the differential assembly.
    8. NOTE: Make sure to install the mainshaft straight in. Failure to install the mainshaft correctly may result in damage to the funnel on the clutch housing.
  8. Install the input shaft assembly, mainshaft assembly and reverse gear idler shaft assembly as a set.
  9. Install the 1st/2nd gear shift fork.
  10. Install the 1st/2nd gear shift rod.
  11. Install a new 1st/2nd gear shift fork roll pin.
  12. Install the 1st/2nd gear shift finger.
  13. Install a new 1st/2nd gear shift finger roll pin.
  14. Install the 1st/2nd gear check sleeve (pin).
  15. Install the 3rd/4th gear shift finger.
  16. Install the 3rd/4th gear shift fork.
  17. Install the 3rd/4th gear shift rod.
  18. Install 2 new circlips.
    Fig 4: Locating Circlips
    G06098228Courtesy of FORD MOTOR CO.
  19. Install a new 3rd/4th gear shift finger roll pin.
  20. Install the 3rd/4th gear shift rod roll pin.
  21. Install the 2 steel balls and the interlock pin.
  22. Install the 5th/reverse gear bracket.
  23. Install the 5th/reverse gear shift rod.
  24. Install the 5th gear shift fork.
  25. Install 2 new circlips.
    Fig 5: Identifying 5th/Reverse Gear Shift Rod And Circlips
    G06098227Courtesy of FORD MOTOR CO.
  26. Install a new 5th gear shift fork roll pin.
  27. Install the reverse gear shift fork.
  28. Install the reverse gear shift fork rod.
  29. Install the shifter cap.
  30. Lift the reverse gear shift fork and insert the cam part of the 5th/reverse gear bracket into the reverse level bracket.
    Fig 6: Inserting Cam Part Of 5th/Reverse Gear Bracket Into Reverse Level Bracket
    G06098323Courtesy of FORD MOTOR CO.
  31. Install the reverse lever bracket bolts.
    • Tighten to 14 Nm (124 lb-in).
  32. Install the magnet.
  33. Install a new LH halfshaft oil seal.
  34. Install a new plug.
  35. Using a depth micrometer and a straightedge, measure and record the depth from the mating surface of the transaxle case to the differential side bearing adjustment shim mounting surface. Record this measurement as L1.
    Fig 7: Measuring And Record Depth From Mating Surface Of Transaxle Case
    G06098324Courtesy of FORD MOTOR CO.
  36. Using a depth micrometer and a straightedge, measure and record the depth from the mating surface of the clutch housing to the differential side bearing outer race outer surface. Record this measurement as L2.
    • Install the differential side bearing outer race on the differential bearing.
    • Holding the outer race in position using hand pressure, rotate the differential 5 times to seat the bearing races.
    Fig 8: Measuring And Record Depth From Mating Surface Clutch Housing To Differential Side Bearing
    G06098325Courtesy of FORD MOTOR CO.
    37. NOTE: Do not use more than 2 shims to achieve the desired shim thickness.
    NOTE: Shims are available in thicknesses from 0.48-0.92 mm (0.0189-0.0366 in) in 0.04 mm (0.00157 in) increments.
  37. Select the shims to allow a preload of 0.15-0.21 mm (0.0059-0.0083 in) using the following formula: shim thickness = (L1-L2) + preload.
  38. Install the differential side bearing adjustment shim.
    39. NOTE: Do not exceed 120°C (248°F) or damage to the transaxle case may occur.
  39. Heat the transaxle case to 100°C (212°F) and install a new differential side bearing outer race.
  40. Temporarily install the mainshaft, mainshaft bearing and circlip.
  41. Temporarily assemble the transaxle case.
  42. Temporarily install and tighten the transaxle case bolts
  43. Using the Dial Indicator Gauge with Holding Fixture, measure and record the depth of the transaxle case to the mainshaft bearing surface when the circlip is expanded and mainshaft is raised to contact the transaxle case.
    Fig 9: Measuring Depth Of Transaxle Case To Mainshaft Bearing Surface
    G06098326Courtesy of FORD MOTOR CO.
  44. Release the circlip and allow the mainshaft to lower and engage the circlip. Measure and record the depth of the transaxle case to the mainshaft bearing surface.
    45. NOTE: Do not use more than one shim to achieve the desired shim thickness.
    NOTE: Shims are available in thicknesses from 0.44-1.08 mm (0.017-0.043 in) in 0.04 mm (0.00157 in) increments.
  45. Select the correct shim to allow an end play of 0.00-0.06 mm (0.00-0.0024 in).
  46. Remove the transaxle case.
  47. Install the mainshaft adjustment shim.
  48. Install a new mainshaft snap ring.
  49. Using a depth micrometer and a straightedge, measure and record the depth from the mating surface of the transaxle case to the input shaft adjustment shim mounting surface. Record this measurement as L1.
    Fig 10: Measuring And Record Depth From Mating Surface Of Transaxle Case To Input Shaft
    G06098327Courtesy of FORD MOTOR CO.
  50. Using a depth micrometer and a straightedge, measure and record the depth from the mating surface of the clutch housing to the input shaft bearing outer race outer surface. Record this measurement as L2.
    Fig 11: Measuring And Record Depth From Mating Surface Of Clutch Housing To Input Shaft Bearing
    G06098328Courtesy of FORD MOTOR CO.
    51. NOTE: Do not use more than one shim to achieve the desired shim thickness.
    NOTE: Shims are available in thicknesses from 0.40-1.72 mm (0.016-0.068 in) in 0.04 mm (0.00157 in) increments.
  51. Select the shims to allow an end play of 0.00-0.06 mm (0.00-0.0024 in) using the following formula: shim thickness = (L1-L2) -end play.
  52. Install the input shaft adjustment shim.
  53. Using a depth micrometer and a straightedge, measure and record the depth from the mating surface of the transaxle case to the reverse idler shaft adjustment shim mounting surface. Record this measurement as L1.
    Fig 12: Measuring Mating Surface Of Transaxle Case To Reverse Idler Shaft
    G06098329Courtesy of FORD MOTOR CO.
  54. Using a depth micrometer and a straightedge, measure and record the depth from the mating surface of the clutch housing to the reverse idler shaft bearing surface. Record this measurement as L2.
    Fig 13: Measuring Depth From Mating Surface Of Clutch Housing
    G06098330Courtesy of FORD MOTOR CO.
    55. NOTE: Do not use more than one shim to achieve the desired shim thickness.
    NOTE: Shims are available in thicknesses from 1.76-2.64 mm (0.069-0.104 in) in 0.04 mm (0.00157 in) increments.
  55. Select the shims to allow an end play of 0.04-0.14 mm (0.001-0.005 in) using the following formula: shim thickness = (L1-L2) -end play.
  56. Install the reverse idler shaft adjustment shim.
  57. Install the oil gutter.
  58. Install the baffle plate.
  59. Apply a continuous bead of silicone gasket and sealant.
    Fig 14: Identifying Sealant Applying Area
    G06098331Courtesy of FORD MOTOR CO.
  60. Spread the mainshaft snap ring and install the transaxle case.
  61. Install a new bore plug.
    62. NOTE: The black-colored bolt must be installed new, in the correct position, and tightened to 65 Nm (48 lb-ft).
    Fig 15: Locating Transaxle Case Bolts
    G06098332Courtesy of FORD MOTOR CO.
  62. Install the transaxle case bolts.
    • Tighten to 52 Nm (38 lb-ft) in a cross pattern.
  63. Install the 3 check balls.
  64. Install the 5th/reverse gear shift check sleeve.
  65. Install the springs. Refer to the following table for the correct color and location:
    COLOR REFERENCE

    Color Location
    Yellow 5th/reverse gear shift rod
    Blue 3rd/4th gear shift rod
    White 1st/2nd gear shift rod
  66. Install a new check plug in the 5th/reverse gearshift rod.
  67. Install new check plugs in the 1st/2nd gear shift rod and the 3rd/4th gear shift rod.
  68. Install a new shift assembly O-ring seal.
  69. Install the shift assembly.
  70. Install 4 new shift assembly bolts.
    • Tighten to 7 Nm (62 lb-in).
  71. Install a new stopper bolt.
    • Tighten to 28 Nm (21 lb-ft).
  72. Install a new shift check bolt.
    • Tighten to 24 Nm (18 lb-ft).
  73. Install the reverse switch.
  74. Install the transaxle drain plug, the fill plug, and the fill level inspection plug.
    • Install new plug washers.
    • Tighten the drain plug and the fill level inspection plug to 35 Nm (26 lb-ft).
    • Tighten the transaxle fill plug to 35 Nm (26 lb-ft).


MATERIAL SPECIFICATIONS

Item Specification
High Performance DOT 3 Motor Vehicle Brake Fluid PM-1-C (US); CPM-1-C (Canada) WSS-M6C62-A or WSS-M6C65-A1
Premium Long-Life Grease XG-1-C or XG-1-K (US); CXG-1-C (Canada) ESA-M1C75-B
SAE 75W-90 API GL-4 Gear Oil XT-4-QGL WSS-M2C203-A1
  1. Do not lubricate the splines on the input shaft.
    2. WARNING: Secure the assembly to the jack. Avoid any obstructions while lowering and raising the jack. Contact with obstructions may cause the assembly to fall off the jack, which may result in serious personal injury.
  2. Raise and position the transaxle to the engine.
  3. Install the 2 short transaxle-to-engine bolts.
    • Tighten to 47 Nm (35 lb-ft).
  4. Install the LH transaxle support insulator bracket.
    • Raise the transaxle, aligning the bracket to the insulator. Install the 3 nuts.
    • Tighten to 40 Nm (30 lb-ft).
  5. Install the rear transaxle support insulator.
    • Install the nuts, the bolt and through bolt. Tighten the through bolt to specification. Do not tighten the nuts and bolt at this time.
    • Tighten to 103 Nm (76 lb-ft).
  6. After removing the transmission jack, install 4 long transaxle-to-engine bolts.
    • Tighten to 47 Nm (35 lb-ft).
  7. Tighten the LH transaxle support insulator through bolt to specification.
    • Tighten to 103 Nm (76 lb-ft).
  8. Tighten the transaxle rear support insulator fasteners to specification.
    • Install the nuts and bolt.
    • Tighten to 80 Nm (59 lb-ft).
  9. Remove the Engine Support Bar that was installed during the removal procedure.
  10. Install the RH engine support bolt.
    • Tighten to 90 Nm (66 lb-ft).
  11. Install the 3 upper transaxle-to-engine bolts.
    • Tighten to 47 Nm (35 lb-ft).
    Fig 1: Identifying Upper Transaxle-To-Engine Bolts
    G06098213Courtesy of FORD MOTOR CO.
  12. Install the intermediate shaft and the 2 nuts.
    • Tighten to 27 Nm (20 lb-ft).
    Fig 2: Identifying Intermediate Shaft Retaining Nuts
    G06095032Courtesy of FORD MOTOR CO.
  13. Install the RH half shaft onto the intermediate shaft.
    Fig 3: Locating RH Half Shaft
    G06098335Courtesy of FORD MOTOR CO.
  14. Connect the RH ball joint.
    • Tighten to 63 Nm (46 lb-ft).
  15. Connect the RH stabilizer bar link.
    • Tighten to 55 Nm (41 lb-ft).
  16. Connect the RH tie-rod end.
    • Tighten to 55 Nm (41 lb-ft).
  17. Install the brake hose and the clip.
  18. Position the ABS wire then install the bolt.
  19. Install the LH halfshaft.
  20. Connect the LH ball joint.
    • Tighten to 63 Nm (46 lb-ft).
  21. Connect the stabilizer bar link.
    • Tighten to 55 Nm (41 lb-ft).
  22. Connect the RH tie-rod end.
    • Tighten to 55 Nm (41 lb-ft).
  23. Connect the brake hose and install the clip.
  24. Position the ABS wire then install the bolt.
  25. Install the starter motor assembly. For additional information, refer to STARTING SYSTEM .
  26. Install the front-to-aft crossmember.
    1. Position the crossmember.
    2. Install the 2 bolts and a nut.
      • Tighten the bolts to 90 Nm (66 lb-ft).
      • Tighten the new nut to 175 Nm (129 lb-ft).
    Fig 4: Identifying Crossmember Nut And Bolts
    G06098336Courtesy of FORD MOTOR CO.
  27. Install the transaxle front support insulator through bolt.
    • Tighten to 115 Nm (85 lb-ft).
  28. Install the crossmember.
    1. Position the crossmember.
    2. Install the bolts.
      • Tighten to 115 Nm (85 lb-ft).
    Fig 5: Identifying Crossmember Bolts
    G06098337Courtesy of FORD MOTOR CO.
  29. Connect the clutch hydraulic tube.
    1. Position the clutch hydraulic tube.
    2. Connect the clutch hydraulic tube from the clutch slave cylinder.
    3. Install the clutch hydraulic tube bracket-to-transaxle bolt.
      • Tighten to 2.5 Nm (22 lb-in).
    Fig 6: Installing Clutch Hydraulic Line Bracket-To-Transaxle Bolt
    G06098338Courtesy of FORD MOTOR CO.
  30. Install the shift cable bracket.
    1. Position the shift cable bracket.
    2. Install the 3 bolts.
      • Tighten to 22 Nm (16 lb-ft).
    Fig 7: Identifying Shift Cable Bracket And Bolts
    G06098339Courtesy of FORD MOTOR CO.
  31. Connect the shift cables.
    Fig 8: Locating Shift Cables
    G06098209Courtesy of FORD MOTOR CO.
  32. Connect the reverse switch and Vehicle Speed Sensor (VSS) connectors.
  33. Install the wiring harness bracket nut.
    • Tighten to 12 Nm (106 lb-in).
    Fig 9: Locating Wiring Harness Bracket Nut
    G06098207Courtesy of FORD MOTOR CO.
  34. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  35. Install the air cleaner assembly. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING - 2.5L .
    36. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury.
    NOTE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.
  36. Fill and bleed the clutch. For additional information, refer to MANUAL TRANSAXLE/TRANSMISSION AND CLUTCH - GENERAL INFORMATION .
  37. Install the LH side splash shield.
    1. Position the LH splash shield.
    2. Install the 2 screws.
    Fig 10: Identifying LH Splash Shield With Screws
    G06098342Courtesy of FORD MOTOR CO.
  38. Install the wheel and tire. For additional information, refer to WHEELS & TIRES .
About FixVault