Steps 1-70

Special Tool(s)

CAUTION: Whenever the transaxle has been disassembled, the bearing preload must be adjusted. The input shaft, output shaft and differential bearing preload can be adjusted by selecting shims to insert between the bearing races and the case on the case side.





1. Using the special tool, install the input shaft seal.





2. Install the input shaft bearing cup into the flywheel housing.





3. Install the input shaft.





4. Position the bearing cup onto the bearing.





5. Position the special tools.





6. Install the transaxle case.
1. Position the transaxle case.
2. Install the bolts.





7. Mount a dial indicator to the transaxle case.
8. Rotate the input shaft to seat the bearings.





9. Zero the dial indicator.





10. CAUTION: The shaft must be lifted equally on both sides or it may cock to one side, resulting in an incorrect reading.

Rotate the input shaft until the dial indicator returns to zero then raise the input shaft and read the end play.





11. Repeat the previous step to obtain three readings within 0.10 mm (0.004 inch) of each other. Use the formula below to select the correct shim size.

12. CAUTION: Do not use more than two shims.

From Shim Selection Kit meeting Ford specification, select the shim(s) that is closest to (or slightly thinner than) the final shim size determined in the previous step.
13. Remove the transaxle case, special tools, bearing cup, and input shaft.





14. Install the shim.





15. Using the special tools, install the input shaft bearing cup.





16. Install the funnel.





17. Using the special tools, install the output shaft bearing cup.





18. Install the output shaft.





19. Position the bearing cup onto the bearing.





20. NOTE: The gauge halves must be turned to eliminate any gap between them.

Position the special tools.





21. Install the transaxle case.
1. Position the transaxle case.
2. Install the bolts.





22. Install a dial indicator on the transaxle case.
23. Rotate the output shaft to seat the bearings.





24. Zero the dial indicator.





25. CAUTION: The shaft must be lifted equally on both sides or it may cock to one side, resulting in an incorrect reading.

Rotate the output shaft until the dial indicator returns to zero then raise the output shaft and read the end play.





26. Repeat the previous step to obtain three readings within 0.10 mm (0.004 inch) of each other. Use the formula below to select the correct shim size.

27. CAUTION: Do not use more than two shims.

From Shim Selection Kit meeting Ford specification, select the shim(s) that is closest to (or slightly thinner than) the final shim size determined in the previous step.
28. Remove the transaxle case, special tools, bearing cup and output shaft.





29. Install the shim.





30. Using the special tools, install the output shaft bearing cup.





31. Using the special tools, install the differential bearing cup into the flywheel housing.





32. Install the differential.





33. Position the bearing cup onto the bearing.





34. NOTE: The gauge halves must be turned to eliminate any gap between them.

Position the special tools.





35. Install the transaxle case.
1. Position the transaxle case.
2. Install the bolts.





36. Using the special tool, adjust gauge until the free play is removed. Turn gauge back together.





37. Insert the special tool through the transaxle case and engage the differential pinion shaft.





38. Using the special tools, adjust gauge until the differential rotation is within specification.





39. Measure the gap in the special tool.
40. Add 0.15 mm (0.0059 inch) to the measurement to achieve the final clearance.

41. CAUTION: Do not use more than two differential shims.





Use the following chart to select the differential bearing shims that are closest to (or slightly larger than) the value obtained in Step 40.
42. Remove the transaxle case, special tools, bearing cup, and differential.





43. Install the differential bearing cup shim(s) into the transaxle case.





44. Using the special tools, install the differential bearing cup into the transaxle case.





45. NOTE: Transaxle case side shown, flywheel housing side similar.

Using the special tool, install the halfshaft seals.





46. Install the reverse lever and shaft.
1. Position the reverse lever.
2. Install the reverse lever shaft.





47. Install the reverse lever roll pin.





48. Install the vent tube and the vent tube bolts.





49. Using the special tool, install the shift control shaft seal.





50. NOTE: Install the boot with the drain hole facing downward when installed in the vehicle.

Install the shift control shaft assembly.





51. Install a new roll pin.





52. Install the shift control shaft selector lever.
1. Position the shift control shaft selector lever.
2. Install the shift control shaft selector lever bolt.





53. Install the shift control selector plate and spacer.
1. Position the shift control selector plate and spacer.
2. Install the bolts.





54. Install the differential.





55. Install the output and input shafts as an assembly.





56. Install the gear shifter fork and main shift control shaft assembly, spring and detent ball.
57. Shift into second and fourth gears.





58. Install the shift lever shaft and shift fork selector lever.
1. Install the shift fork selector lever.
2. Install the shift lever shaft.





59. Install the shift lever shaft roll pin.





60. Install the shift control shaft and shift gate.
1. Install the shift gate.
2. Install the shift control shaft.





61. Install the shift gate bolt.





62. Install the reverse idler gear.
1. Install reverse idler gear.
2. Install reverse idler gear shaft.





63. Install the magnet.





64. Position the gear selector arm and reverse idler gear shaft.
1. Align the end of the gear selector interlock sleeve with the gear selector arm.
2. Face the reverse idler gear shaft hole in the direction shown.

65. CAUTION: The transaxle case must be installed within four minutes after applying silicone gasket and sealant.

Apply a small bead of silicone gasket and sealant to the transaxle mating surface.





66. Install the transaxle case.
1. Position the transaxle case.
2. Install the 15 bolts.





67. Install the lock bolt, spring, and ball.





68. CAUTION: Make sure that the shift rail guide bolt is in the groove of the shift rail.

Install the reverse idler shaft lock bolt and shift rail guide bolt.





69. Install the fifth speed gear and fifth gear spacer.
1. Install fifth speed gear.
2. Install the fifth gear spacer.





70. Install the fifth gear bushing.