Service Procedure

1. Remove the transaxle from vehicle by referring to the 1996 Contour/Mystique Service Manual, Section 07-03.

2. Disassemble the transaxle per the following Steps 2a-2k.





a. Mount the transaxle in Bench Mounted Holding Fixture T57L-500-B (Figure 1).

b. Remove the selector mechanism, ensuring the selector mechanism is in neutral.





^ Remove six (6) bolts retaining control select lever cover (Figure 2).

^ Withdraw the complete selector mechanism.

NOTE:
DO NOT REMOVE LOCATING DOWELS.





c. Remove sixteen (16) bolts retaining transaxle housing to clutch housing (Figure 3). Note the length and location of bolts for reassembly.

CAUTION:
DO NOT DAMAGE THE HOUSING.





d. Using a block of wood and pry bar, apply force at the location shown in Figure 4 to separate the transaxle housings.

e. Lift the transaxle housing off the clutch housing.





f. Lift out the differential assembly. Remove magnet (Figure 5).





g. Pull the long and short selector fork rails from the case. Remove the 1st/2nd gear shift fork (Figure 6).





h. Swing the 5th/reverse gear shift fork to the side. Rotate and remove the 3rd/4th gear shift fork (Figure 7). Remove the 5th/reverse gear selector fork.





i. Release the gear idler shaft mounting. Remove two (2) reverse idler gear shaft support bracket retaining bolts. Swing input and output shafts to the side. The reverse gear idler shaft mounting should lift up (Figure 8). The reverse gear idler shaft mounting remains in the transaxle.





j. Leave the input shaft and output shaft together out of the transaxle housing (Figure 9).

k. Remove the reverse gear idler shaft mounting and the reverse gear idler with the needle roller bearing and thrust washers.

3. Disassemble the input shaft per the following Steps 3a-3e.





a. Remove the bearing outer cups and shim of the input shaft in clutch housing using Puller T58L-101-B and Stator and Driven Sprocket Bearing Remover T86P-70043-A (Figure 10).





b. Using Bearing Pulling Attachment D84L-1123-A, or equivalent, press off the 5th gear wheel with the input shaft bearing (Figure 11).

^ 1) Slide the snap ring up out of the annular groove until it sits below the input shaft bearing





^ 2) Press off 5th gear together with the snap ring and input shaft bearing (Figure 12)





c. Remove 4th gear, needle roller bearing, and 3rd/4th gear synchronizer ring from the input shaft (Figure 13).





d. Remove snap ring and 3rd/4th gear synchronizer assembly from input shaft (Figure 14).

^ Remove the snap ring

^ Pull off the synchronizer assembly

CAUTION:
HANDLE THE INNER SYNCHRONIZER RING AND SYNCHRONIZER CONE VERY CAREFULLY.





NOTE:
TRANSAXLES MARKED WITH BUILD CODE 4E, 4F, OR 4G01A - 4G07B HAVE SINGLE SYNCHRONIZERS FOR 3RD GEAR. TRANSAXLES MARKED WITH BUILD CODE 4G08A OR LATER ARE BUILT WITH DOUBLE SYNCHRONIZERS. THE BUILD CODE IS STAMPED ON THE TRANSAXLE BELOW THE PART NUMBER (FIGURE 15). VEHICLES WITH SINGLE SYNCHRONIZATION FOR 3RD GEAR WILL BE FITTED WITH DOUBLE SYNCHRONIZERS USING THE PROCEDURE IN THIS TSB ARTICLE.





e. Remove outer synchronizer ring, synchronizer cone, inner synchronizer ring, 3rd gear, and needle roller bearing (Figure 16).

4. Reassemble the input shaft per the following Steps 4a-4e.

NOTE:
DO NOT OIL INPUT SHAFT BEARINGS WHICH ARE TO BE USED AGAIN. NEW INPUT SHAFT BEARINGS CAN BE USED WITHOUT ANY TREATMENT. ALL PARTS OTHER THAN INPUT SHAFT BEARINGS SHOULD BE LUBRICATED WITH MOTORCRAFT MERCON(R) MULTI-PURPOSE AUTOMATIC TRANSMISSION FLUID (ATF) (XT-2-QDX), OR EQUIVALENT MEETING MERCON(R) SPECIFICATION, PRIOR TO REASSEMBLY.

NOTE:
ALL THE PARTS LISTED IN THE TABLE AT THE END OF THIS TSB ARTICLE MUST BE REPLACED, EVEN IF NO WEAR IS APPARENT, TO OBTAIN SATISFACTORY REPAIR.

a. Install a new 3rd Gear (F5RZ-7M163-AA). Install the Inner Synchronizer Ring (93ZT-7107-DA), Synchronizer Cone (93ZT-7M000-BA), and Outer Synchronizer Ring (93ZT-7107-CA) contained in kit F5RZ-7124-BA (Figure 16).





b. Install a new 3rd/4th Gear Synchronizer Assembly (F5RZ-7124-B) contained in kit F5RZ-71 24-BA with the LARGE COLLAR FACING OUT (Figure 17). Use a new Snap Ring (W700403-S300).





c. Install 3rd/4th gear synchronizer ring, needle roller bearing, and new 4th Gear (F5RZ-7112-AA) to input shaft (Figure 18).





d. Press 5th gear onto input shaft using a suitable length of tubing as a driver (Figure 19). Fit a new Snap Ring (W700405-S300).





e. Press input shaft bearing onto input shaft using a suitable length of tubing as a driver (Figure 20).

5. Measure the shims per the following Steps 5a-5m:

NOTE:
DO NOT OIL TAPER ROLLER BEARING WHICH IS TO BE USED AGAIN. NEW TAPER ROLLER BEARING CAN BE FITTED WITHOUT ANY TREATMENT.





a. Prepare the input and output shafts for installation to the case by engaging 4th gear on the input shaft (Figure 21).








b. Assemble the input shaft and the output shaft together and fit them in the transmission housing (Figures 22 and 23).

c. Measuring shim to be fitted to the input shaft is 1.00 mm.





d. Cool the bearing cups. Heat the area of the housing to approximately 80°C (175°F) . Fit the measuring shim and the bearing cup in the housing section at the clutch end (Figure 24). Using Bearing Cup Replacer T94P-7025-BH, Driver Handle T8OT-4000-W, and soft-faced hammer.





e. Fit the housing - clutch end (Figure 25).





f. Secure the housing - clutch end (Figure 26).





g. Attach Measuring Fixture T94P-4451-AH on the 4th gear wheel face (Figure 27).





h. Prepare the input shaft for measuring by installing Pinion Spline Socket T94P-7025-EH to the input shaft. Rotate shaft approximately 20 times to settle bearings (Figure 28).





i. Set up the dial indicator with the transaxle upright, install Dial Indicator with Bracketry, TOOL-4201-C, or equivalent, to transaxle case. Position stem of dial indicator to end of input shaft. Set the dial to zero (Figure 29).





j. Measure the input shaft end float (Figure 30).

^ Lift the input shaft with a lever

^ Note the resulting measurement. Record a dial indicator reading (e.g., 0.22 mm) with input shaft in full up position.

k. Repeat Steps 5h-5j 3 times and calculate the average measurement (e.g., 0.22 + 0.23 + 0.21 divided by 3 = 0.22 mm).





l. Calculate the correct shim thickness for an axial lash of 0.08 mm using the example as shown.

m. Find the shim with the thickness calculated in Step 5l in Shim kit F5RZ-7L172-AA (the shim thickness is stamped on the shim). Fit the shim and bearing cups as described in Step 5d.

6. Reassemble the transaxle per the following Steps 6a-6m.





a. Fabricate an installation hook of 1/8" diameter wire to install the reverse gear idler (Figure 31).





b. Fit the reverse gear idler using the fabricated hook (Figure 32).

c. Lubricate input shaft, output shaft and differential gears and bearings with clean Motorcraft MERCON(R) Multi-Purpose Automatic Transmission Fluid (ATF) (XT-2-QDX), or equivalent meeting MERCON(R) specification.

NOTE:
OIL THE TAPER ROLLER BEARINGS.








d. Fit the input and output shafts together (Figure 33). Remove the installation hook. Press the reverse gear idler shaft mounting down. Apply Gasket Eliminator (E1FZ-19562-A) or equivalent meeting Ford specification WSK-M2G348-A4, to the bolts and screw them in (Figure 34).





e. Make sure 3rd/4th gear synchronizer selector ring is in the neutral position. Install the 5th/reverse gear shift fork and swivel it to one side (Figure 35).





f. Install new 3rd/4th Gear Shift Fork (F5RZ-7230-BA) (Figure 36).

g. Install 1st/2nd gear shift fork onto long selector fork rail. Engage 1st/2nd gear shift fork to the synchronizer shifter ring while installing LONG selector fork rail into its recess in the bottom of the transaxle case.





h. Install SHORT selector fork rail through the 3rd/4th gear shift fork and into its recess in the bottom of the transaxle case. When installed correctly, selector fork rails are the same height (Figure 37).





i. Lubricate differential assembly gear and bearings with clean Motorcraft MERCON(R) Multi-Purpose Automatic Transmission Fluid (ATF) (XT-2-QDX) or equivalent meeting MERCON(R) specification. Install the differential assembly into the transaxle case. Install the magnet into its recess in the case (Figure 38).





j. Clean and dry transaxle housing sealing face. Apply a 2 mm (0.08") bead of Gasket Eliminator (E1FZ-19562-A), or equivalent meeting Ford specification WSK-M2G348-A4, to transaxle case sealing face (Figure 39).

NOTE:
TRANSAXLE CASE RETAINING BOLTS MUST BE TIGHTENED TO SPECIFICATION WITHIN 15 MINUTES OF SEALER APPLICATION.

NOTE:
THE TRANSAXLE HOUSING MUST NEVER BE TURNED OVER TO TIGHTEN THE BOLTS.





k. Install clutch side transaxle case to gear side transaxle case engaging the input shaft, output shaft and differential bearings with their races. Install the sixteen (16) transaxle case retaining bolts and tighten to 38-52 Nm (28-38 lb-ft) working diagonally (Figure 40).





l. Clean and dry the transaxle case sealing surface where the control select lever cover is to be installed and apply a 2 mm (0.08") bead of Gasket Eliminator (E1FZ-19562-A), or equivalent meeting Ford specification WSK-M2G348-A4, to the surface. Install the control select lever cover to the transaxle case. Install the control select lever cover retaining bolts and tighten the bolts to 11 N.m (8 lb-ft) in an alternate pattern (Figure 41).

m. Select 4th gear. Measure the turning torque. If the turning torque is too high, all the measurements (to establish the required shim thickness) done in Step 5 must be repeated.

7. Reinstall the transaxle into the vehicle by referring to the 1996 Contour/Mystique Service Manual, Pages 07-03-52 through 07-03-56.