Manual Transaxle (G6M): Disassembly: Transaxle

SPECIAL TOOLS

	Holding Fixture 307-003 (T57L-500-B)
	Turning Torque Socket, Transmission 308-160 (T88C-7025-GH)

NOTE: Clean the transaxle exterior before disassembly.

NOTE: Clean all removed parts and all sealing surfaces with solvent, and dry with compressed air.

NOTE: Clean out all holes and passages with compressed air and verify that there are no obstructions.

1. Mount the transaxle to the Holding Fixture.
   Fig 1: Mounting Transaxle To Holding Fixture (307-003)

   Courtesy of FORD MOTOR CO.
2. Remove the clutch release fork and bearing.
   NOTE: May need to use a screwdriver to pry the clutch release fork off the anchor bolt, if needed.
   1. Remove the clutch release bearing.
   2. Remove the clutch release fork and diaphragm.
      Fig 2: Identifying Clutch Release Bearing And Clutch Release Fork

      Courtesy of FORD MOTOR CO.
3. If necessary, remove the anchor bolt.
   Fig 3: Locating Anchor Bolt

   Courtesy of FORD MOTOR CO.
4. Remove the bolt and the Vehicle Speed Sensor (VSS).
   Fig 4: Locating Vehicle Speed Sensor And Bolt

   Courtesy of FORD MOTOR CO.
5. Remove the reversing lamp switch wiring harness retainer bolt and reversing lamp switch.
   Fig 5: Locating Reversing Lamp Switch Wiring Harness Retainer Bolt And Reversing Lamp Switch

   Courtesy of FORD MOTOR CO.
6. Shift the transaxle into the NEUTRAL position.
7. Remove the 9 case cover bolts and the case cover.
   Fig 6: Locating Case Cover And Mounting Bolts

   Courtesy of FORD MOTOR CO.
8. Remove and discard the 5th/6th gear shift fork roll pin.
   Fig 7: Locating 5Th/6Th Gear Shift Fork Roll Pin

   Courtesy of FORD MOTOR CO.
9. Shift the 5th/6th gear shift fork to 5th.
   Fig 8: Locating 5th/6th Gear Shift Fork

   Courtesy of FORD MOTOR CO.
NOTE: Do not reuse locknuts.
10. Remove the primary and secondary shaft locknuts.
    1. Using the Transmission Turning Torque Socket, keep the input shaft from turning.
    2. Using a punch, release the locking tabs from the shafts. Remove and discard the primary and secondary shaft locknuts.
       Fig 9: Identifying Primary And Secondary Shaft Locknuts

       Courtesy of FORD MOTOR CO.
NOTE: Make sure the tabs of the suitable tool are securely positioned on the gear or damage to the gear may occur.
Fig 10: Removing Bearing And 6th Gear From Secondary Shaft Using Suitable Tool
Courtesy of FORD MOTOR CO.
11. Using a suitable tool, remove the bearing and 6th gear from the secondary shaft.
NOTE: Make sure the tabs of the suitable tool are securely positioned on the gear or damage to the gear may occur.
Fig 11: Removing Bearing And 6th Gear From Primary Shaft Using Suitable Tool
Courtesy of FORD MOTOR CO.
12. Using a suitable tool, remove the bearing and 6th gear from the primary shaft.
13. Remove the gear sleeve.
    Fig 12: Locating Gear Sleeve

    Courtesy of FORD MOTOR CO.
14. Remove the 5th/6th shift fork and synchronizer assembly.
    Fig 13: Locating 5th/6th Shift Fork And Synchronizer Assembly

    Courtesy of FORD MOTOR CO.
15. Remove the spacer and the gear sleeve.
    Fig 14: Locating Spacer And Gear Sleeve

    Courtesy of FORD MOTOR CO.
16. Remove the 5th speed primary and secondary gears.
    Fig 15: Locating 5th Speed Primary And Secondary Gears

    Courtesy of FORD MOTOR CO.
    NOTE: Make sure the transaxle is in neutral.
17. Remove the reverse idler shaft lock bolt and shift rail guide bolt.
    Fig 16: Locating Reverse Idler Shaft Lock Bolt And Shift Rail Guide Bolt

    Courtesy of FORD MOTOR CO.
18. Remove the shift detent bolt, spring and ball.
    Fig 17: Locating Shift Detent Bolt

    Courtesy of FORD MOTOR CO.
19. Remove the 15 transaxle case bolts and separate the transaxle case.
    • After separating the transaxle cases, position the removed case on its side. Use care not to damage the funnel.
      Fig 18: Locating Transaxle Case Bolts

      Courtesy of FORD MOTOR CO.
20. Remove the funnel bolt and the funnel.
    Fig 19: Locating Funnel

    Courtesy of FORD MOTOR CO.
21. Remove the magnet.
    Fig 20: Locating Magnet

    Courtesy of FORD MOTOR CO.
22. Remove the shift lever shaft pin, then remove the shift lever shaft and shift fork selector lever.
    Fig 21: Locating Shift Lever Shaft Pin, Shift Lever Shaft And Shift Fork Selector Lever

    Courtesy of FORD MOTOR CO.
23. Remove the shift gate bolt.
    Fig 22: Locating Shift Gate Bolt

    Courtesy of FORD MOTOR CO.
24. Remove the shift control shaft and remove the shift gate.
    Fig 23: Locating Shift Control Shaft And Shift Gate

    Courtesy of FORD MOTOR CO.
25. Move the shift forks upward into 2nd and 4th gears.
    Fig 24: Moving Shift Forks Upward Into 2nd And 4th Gears

    Courtesy of FORD MOTOR CO.
26. Remove the reverse idler gear assembly and shift fork.
    Fig 25: Locating Reverse Idler Gear And Shift Fork

    Courtesy of FORD MOTOR CO.
27. Rotate the main shift control shaft clockwise to free the interlock from the 1-2 and 3-4 shift forks.
28. Raise the main shift control shaft until it clears the bore in the transaxle case and remove the main shift control shaft assembly, shift forks.
    Fig 26: Locating Main Shift Control Shaft Assembly And Shift Forks

    Courtesy of FORD MOTOR CO.
29. Remove the primary and secondary shafts at the same time.
    Fig 27: Locating Primary And Secondary Shafts

    Courtesy of FORD MOTOR CO.
30. Remove the differential.
    Fig 28: Locating Differential

    Courtesy of FORD MOTOR CO.
31. For further disassembly of the transaxle case, refer to TRANSAXLE CASE .