Transaxle Disassembly

Transaxle









All Transmissions

1. Using the special tool, install the transaxle.





2. Remove the clutch slave cylinder.
1. Remove the 3 clutch slave cylinder bolts.

2. Remove the clutch slave cylinder.






3. Remove the Vehicle Speed Sensor (VSS).
1. Remove the retaining pin.

2. Remove the VSS (Vehicle Speed Sensor).






4. Remove the reversing lamp switch.





5. Remove the gearshift cables shroud retainers and the gearshift cables shroud.





6. Remove the selector lever.
1. Remove the protective cap.

2. Remove and discard the snap-ring and remove the selector lever.






7. Remove the 2 gearshift cables bracket nuts and remove the gearshift cables bracket.





8. Remove the shift lever snap ring and remove the shift lever.





9. Remove the selector shaft interlock mechanism.





10. Remove the 5th gear cover bolts and remove the 5th gear cover.





Transmissions with Old Style Synchronizer

11. Remove the 5th gear synchronizer unit, selector fork and 5th gear.
1. Remove and discard the circlip.

2. Remove and discard the roll pin.






12. NOTE: Mark the installation position of the gear synchronizer before disassembling.
Disassemble the 5th gear synchronizer unit.

1. Remove the retention plate

2. Remove the synchronizer assembly

3. Remove the synchronizer ring

4. Remove the 5th gear






13. Remove and discard the 5th gear snap ring.





Transmissions with New Style Synchronizer and All Replacement Synchronizers

14. NOTE: Note the position of the components before removal.
Remove the 5th gear synchronizer unit and selector fork.

1. Remove and discard the circlip.

2. Remove and discard the roll pin.






15. NOTE: Note the position of the components before removal.
Disassemble the synchronizer assembly.






16. Remove and discard the 5th gear snap ring and remove the mainshaft 5th gear.





All Transmissions

17. Using the special tool, remove the 5th gear.





18. NOTICE: Do not strike directly on the gear housing mating surfaces or damage can occur.

Remove the 5th gear housing.
1. Remove and discard the 9 bolts and carefully separate the 5th gear housing sections by tapping lightly.

2. Using Motorcraft(R) Metal Surface Prep, clean the 5th gear housing mating surfaces.






19. Remove the input shaft and output shaft retaining rings.
1. Remove and discard the input shaft retaining ring.

2. Remove and discard the output shaft retaining ring.






20. Remove the LH and RH halfshaft seals.

21. NOTICE: Do not use metal scrapers to clean the transaxle gear housing surfaces or damage can occur.

NOTE: Slightly turn the transaxle housing to raise it.

Separate the transaxle housing from the clutch housing.
- Using Motorcraft(R) Metal Surface Prep, clean the transaxle housing and clutch housing mating surfaces.






22. Remove the upper snap-ring from the selector rod guide sleeve.
1. Remove and discard the upper snap-ring.

2. Push the selector rod guide sleeve downwards.






23. Remove the selector rod guide sleeve.
1. Remove and discard the lower snap-ring from the guide sleeve.

2. Pull off the selector rod guide sleeve.






24. NOTE: Install a rubber belt to the auxiliary selector shaft to aid disassembly.
Remove the input and output shaft with the shift forks.






25. Remove the differential and the magnet.





26. Remove the reverse idle gear.





27. Remove the selector rod and locking plate.
1. Remove the selector interlock plate.

2. Remove the 5th/reverse gear selector rod.






28. Remove and discard the input shaft oil seal.





29. Remove output shaft roller bearing.
- Press out the track rollers from the bearing cage.

- Remove the bearing cage.






30. NOTICE: Only use the special tool in the position indicated, otherwise the blanking plug will be forced out of the housing.

Using the special tool, remove the output shaft bearing cone.
- Remove the oil thrower.






31. Remove the bearing cone.





32. Using the special tool, remove the differential bearing cone.