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All Transmissions

    NOTE: Apply transmission fluid to all rotating surfaces.
  1. Clean and check all parts carefully before reassembly.
  2. Using the special tool, install the output shaft roller bearing and bearing cone.
    1. Install the oil thrower.
    2. Install the bearing as far as stop.
    Fig 1: Installing Output Shaft Roller Bearing And Bearing Cone
    G06938134Courtesy of FORD MOTOR CO.
  3. Using the special tool, install the differential bearing cone.
    Fig 2: Installing Differential Bearing Cone
    G06938135Courtesy of FORD MOTOR CO.
  4. Install the shift selector interlock plate and the selector rod.
    1. Install the shift selector interlock plate.
    2. Install the 5th/reverse gear selector rod.
    Fig 3: Identifying Selector Interlock Plate And 5th/Reverse Gear Selector Rod
    G06938104Courtesy of FORD MOTOR CO.
  5. Install the reverse gear idler (as shown in illustration), the differential and the magnet.
    1. Reverse gear idler.
    2. Differential.
    3. Magnet.
    Fig 4: Identifying Reverse Gear Idler, Differential And Magnet
    G06938137Courtesy of FORD MOTOR CO.
  6. Prepare the input and the output shaft for installation.
    1. Position the input shaft and the output shaft together.
    2. Position the 1st and 2nd gear selector fork on the shaft assemblies.
    3. Position the 3rd and 4th gear selector fork on the shaft assemblies.
    Fig 5: Identifying 1st And 2nd Gear Selector Fork On Shaft Assemblies
    G06938138Courtesy of FORD MOTOR CO.
  7. Install the input shaft, output shaft and selector fork assemblies into the transaxle case.
    • Install a rubber band to the selector shaft to aid assembly.
    • Insert the input shaft to a depth of approximately 50 mm (1.968 in) and swivel it slightly to the side.
    • Insert the output shaft to the level of the input shaft and engage the gears.
    • Install the input shaft and the output shaft.
    Fig 6: Installing Input Shaft, Output Shaft And Selector Fork Assemblies Into Transaxle Case
    G06938139Courtesy of FORD MOTOR CO.
  8. Install the selector shaft guide sleeve and new lower snap ring.
    1. Push in the selector shaft guide sleeve.
    2. Install the new lower snap ring.
    Fig 7: Installing Selector Shaft Guide Sleeve And Lower Snap Ring
    G06938140Courtesy of FORD MOTOR CO.
  9. Install the selector shaft guide sleeve new upper snap ring.
    1. Pull up the selector shaft guide sleeve.
    2. Install the new upper snap ring.
    Fig 8: Pulling Up Selector Shaft Guide Sleeve
    G06938141Courtesy of FORD MOTOR CO.
  10. Move the inner gearshift linkage to 5th gear.
    • Turn the selector shaft clockwise until the reverse and 5th gear passage is reached, then press downwards.
    Fig 9: Turning Selector Shaft
    G06938142Courtesy of FORD MOTOR CO.
    11. NOTE: The inner diameters of the Belleville washers are touching.
    Fig 10: Identifying Belleville Washers, Shim And Bearing Cone
    G07980153Courtesy of FORD MOTOR CO.
  11. Install the shim and secure it by staking the edge of the housing.
    1. Belleville washers.
    2. Shim.
    3. Install the bearing cone and secure it by staking the edge of the housing.
  12. Apply Gasket Maker to the transaxle housing.
    Fig 11: Locating Gasket Maker Applying Area On Transaxle Housing
    G06938150Courtesy of FORD MOTOR CO.
  13. Install the transaxle housing bolts and evenly tighten.
    • Tighten to 33 Nm (24 lb-ft).
    Fig 12: Locating Transaxle Housing Bolts
    G06938151Courtesy of FORD MOTOR CO.
    14. NOTE: Use a wooden block.
    Fig 13: Installing Input Shaft And Output Shaft Retaining Rings
    G06938152Courtesy of FORD MOTOR CO.
  14. Install the new input shaft and output shaft retaining rings.
    15. NOTE: Turn the retaining rings so that they are located in the cut-outs in the gasket.
    Fig 14: Locating Retaining Rings
    G06938153Courtesy of FORD MOTOR CO.
  15. Install the special tools.
  16. Install the new 5th gear housing gasket, 5th gear housing and the 9 new 5th gear housing bolts.
    • Tighten to 17 Nm (150 lb-in).
    Fig 15: Locating 5th Gear Housing Gasket, 5th Gear Housing And 5th Gear Housing Bolts
    G06938154Courtesy of FORD MOTOR CO.
    17. NOTE: Remove the transaxle from the special tool 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.
    Fig 16: Installing 5th Gear Wheel Onto Input Shaft
    G06938155Courtesy of FORD MOTOR CO.
  17. Using the special tool and a press, install the 5th gear wheel onto the input shaft.
  18. Install the special tool onto the transaxle.
    Fig 17: Installing Special Tool Onto Transaxle
    G06938083Courtesy of FORD MOTOR CO.
  19. Using the special tool, install the new 5th gear snap ring.
    1. Install the new snap ring onto the special tool.
    2. Install the special tool and push on the new snap ring.
    Fig 18: Installing 5th Gear Snap Ring
    G06938157Courtesy of FORD MOTOR CO.

    Transmissions with Old Style Synchronizer 

    20. NOTE: Align the synchronizer with the marks made during disassembly.
    Fig 19: Identifying 5th Gear, Synchronizer Ring, Synchronizer And Retention Plate
    G06938158Courtesy of FORD MOTOR CO.
  20. Assemble the 5th gear synchronizer assembly:
    1. install 5th gear.
    2. install the synchronizer ring.
    3. install the synchronizer (as shown in illustration).
    4. install the retention plate.
  21. Install the 5th gear synchronizer assembly with selector fork.
    • Install the new roll pin.
    • Install the new circlip.
    Fig 20: Locating Roll Pin And Circlip
    G06938159Courtesy of FORD MOTOR CO.

    Transmissions with New Style Synchronizer and All Replacement Synchronizers 

  22. Install the mainshaft 5th gear.
    Fig 21: Locating Mainshaft 5th Gear
    G07980164Courtesy of FORD MOTOR CO.
    23. NOTE: Make sure that the components are installed to the position noted before removal.
    Fig 22: Inspecting Synchronizer Hub And Sleeve
    G07980165Courtesy of FORD MOTOR CO.
  23. Assemble the synchronizer hub and sleeve.
    24. NOTE: Make sure that the components are installed to the position noted before removal.
    Fig 23: Inspecting Synchronizer Actuators
    G07980166Courtesy of FORD MOTOR CO.
  24. Install the synchronizer actuators.
    25. NOTE: Make sure that the components are installed to the position noted before removal.
    Fig 24: Inspecting Synchronizer Radial Spring
    G07980167Courtesy of FORD MOTOR CO.
  25. Install the synchronizer radial spring.
    26. NOTE: Make sure that the components are installed to the position noted before removal.
    Fig 25: Inspecting Synchronizer Ring
    G07980168Courtesy of FORD MOTOR CO.
  26. Install the synchronizer ring.
  27. Install the synchronizer and selector fork.
    1. Align the marks made during removal.
    2. Install the new circlip.
    3. Install the new roll pin.
    Fig 26: Installing Synchronizer And Selector Fork Roll Pin
    G07980169Courtesy of FORD MOTOR CO.

    All Transmissions 

  28. Apply Silicone Gasket and Sealant evenly to the end cap.
    Fig 27: Applying Silicone Gasket And Sealant On End Cap
    G06938160Courtesy of FORD MOTOR CO.
  29. Install the 5th gear cover and the 5th gear cover bolts.
    • Tighten to 12 Nm (106 lb-in).
    Fig 28: Locating 5th Gear Cover And 5th Gear Cover Bolts
    G06938161Courtesy of FORD MOTOR CO.
    30. NOTE: Install the selector shaft interlock in the neutral position.
    Fig 29: Locating Selector Shaft Interlock
    G06938162Courtesy of FORD MOTOR CO.
  30. Install the selector shaft interlock as shown in illustration.
    31. NOTE: Make sure the selector shaft interlock in the neutral position.
    Fig 30: Locating Selector Interlock Mechanism
    G06938163Courtesy of FORD MOTOR CO.
  31. Apply Threadlock and Sealer to the selector interlock mechanism and install.
    • Tighten to 25 Nm (18 lb-ft).
  32. Install the shift lever.
    Fig 31: Locating Shift Lever
    G06938164Courtesy of FORD MOTOR CO.
  33. Using the special tool, install the halfshaft seal until it engages audibly.
    Fig 32: Installing Halfshaft Seal Using Special Tool
    G06938165Courtesy of FORD MOTOR CO.
  34. Engage 5th gear.
    • Turn the selector shaft clockwise as far as possible and press it in.
    Fig 33: Turning Selector Shaft
    G06938166Courtesy of FORD MOTOR CO.
  35. Install the gearshift cables bracket and the gearshift cables bracket nuts.
    • Tighten to 20 Nm (177 lb-in).
    Fig 34: Locating Gearshift Cables Bracket And Gearshift Cables Bracket Nuts
    G06938167Courtesy of FORD MOTOR CO.
  36. Install the selector lever.
    1. Install the new snap ring.
    2. Install the protective cap.
    Fig 35: Identifying Snap Ring And Protective Cap
    G06938168Courtesy of FORD MOTOR CO.
  37. Install the gearshift cables shroud and gearshift cables shroud fasteners.
    Fig 36: Locating Gearshift Cables Shroud Retainers
    G06938086Courtesy of FORD MOTOR CO.
  38. Install the reversing lamp switch.
    • Tighten to 14 Nm (124 lb-in).
    Fig 37: Locating Reversing Lamp Switch
    G07980063Courtesy of FORD MOTOR CO.
  39. Install the Vehicle Speed Sensor (VSS).
    1. Connect the VSS  .
    2. Install the retaining pin.
    Fig 38: Identifying Vehicle Speed Sensor And Retaining Pin
    G06938170Courtesy of FORD MOTOR CO.
    40. NOTE: Apply adhesive tape to cover the input shaft splines to prevent damage to the input shaft seal.
    Fig 39: Installing Input Shaft Seal Using Special Tool
    G06938171Courtesy of FORD MOTOR CO.
  40. Using the special tools, install the new input shaft seal.
    1. Apply a small amount of adhesive tape to the input shaft.
    2. Put the input shaft seal on the input shaft.
    3. Using the special tool, install the new input shaft seal.
  41. Install the clutch slave cylinder and the clutch slave cylinder bolts.
    1. Apply a small amount of grease to the input shaft.
    2. Install the clutch slave cylinder.
    3. Install the 3 clutch slave cylinder bolts.
      • Tighten evenly to 11 Nm (97 lb-in).
Fig 40: Identifying Clutch Slave Cylinder And Clutch Slave Cylinder Bolts
G06938172Courtesy of FORD MOTOR CO.
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