Assembly

NOTE: Clean and inspect all parts carefully before assembly. Lubricate contact surfaces with clean Motorcraft MERCON(r) Multi-Purpose Automatic Transmission Fluid or equivalent meeting MERCON(r) specification.





1. Install outer selector shaft bushing using Selector Shaft Bearing Remover/Replacer T94P-7025-DH.





2. Install shift lever shaft oil seal using Selector Shaft Seal Remover/Replacer T94P-7025-HH.





3. Install shift lever shaft inner bushing using Selector Shaft Bearing Remover/Replacer T94P-7025-DH.





4. Insert shift lever shaft into its bore in transaxle case. Fit the main shift control shaft block to the end of the shift lever shaft and install the retaining bolt. Tighten bolt to 23 Nm (17 ft. lbs.).





5. Position reverse idler gear shaft in case using mounting bolt as a guide. Drive reverse idler gear shaft until retaining plate contacts the transaxle case and install three bolts. Tighten to 24 Nm (18 ft. lbs.)

NOTE: The reverse idler gear shaft-to-transaxle case fit is an interference fit. The transaxle case must be preheated to 80°C (175°F) in reverse idle gear shaft mounting area using Rotunda Heat Gun 107-R0300 or equivalent before installing reverse idler gear shaft. After heating transaxle case, apply a thin layer of Silicone Rubber D6AZ-19562-AA or BA or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G195-A to mating surface of reverse idler gear shaft retaining plate.
6. Cool outer bearing races to at least 8°C (46°F) by placing in a freezer for approximately 30 minutes.

CAUTION: Bearing races for input shaft, output shaft and differential assemblies require a heating and cooling procedure and special tools for installation into either transaxle case half. This procedure must be followed to prevent premature wear of cases and to provide accurate preload measurements.

NOTE: Shims are used between the transaxle case (clutch side) and input shaft, output shaft and differential bearing races for preload of those assemblies. A measurement procedure, using specific measurement shims, is used to determine which thickness shims are required for final assembly. These shims are supplied in the service shim kit. The purpose of the service shim is to start preload measurement at a predetermined value. Install specified service shims under the bearing races of the clutch case half of the transaxle. Each time the bearing races are installed, the heating-cooling procedure and special tools must be used.

7. Heat gear side transaxle case to 80°C (194°F) using Rotunda Heat Gun 107-R0300 or equivalent in bearing race area for output shaft bearing race.





8. Install output shaft bearing race to transaxle case using Bearing Cup Replacer T94P-7025-BH Driver Handle T80T-4000-W and a soft-faced hammer.
9. Repeat heat and installation procedure until all three races are installed.
10. Chill clutch side transaxle case bearing races to 8°C (46°F) in a freezer.
11. Heat the clutch housing to 80°C (194°F) using Rotunda Heat Gun 107-R0300 or equivalent in bearing race area for race being installed.





12. Install service shims from the Service Shim Kit to clutch side transaxle case. The service shim thickness is specified for each component. This shim thickness is critical. Double check measurements with a micrometer.
13. Install bearing race to the clutch side transaxle case using Bearing Cup Replacer T94P-7025-BH, Driver Handle T80T-4000-W and soft-faced hammer.
14. Repeat heat and installation procedure until all three service shims and bearing races are installed.





15. Prepare the input and output shafts for installation to the case by engaging 4th gear on the input shaft as shown.
16. Assemble the input and output shafts as shown. Lower them into transaxle case together.

NOTE: Do not lubricate the tapered roller bearings at this time. Bearings will be lubricated after preload measurements are obtained.





17. Lower the differential assembly into the case.

NOTE: Do not lubricate the tapered roller bearings at this time. Bearings will be lubricated after preload measurements are obtained.





18. Lower clutch side transaxle case down onto gear side transaxle case.

NOTE: Do not use sealer on the case halves at this time. Sealer will be applied at time of final assembly.





19. Install and tighten 16 transaxle case-to-clutch housing bolts to 38-51 Nm (28-38 ft. lbs.).





20. Install Measuring Fixture T94P-4451-AH to transaxle case at control select lever cover opening using three control select lever cover mounting bolts. Position measuring bar on the 4th gear face. This bracket will be used to check output shaft end-play.





21. Install Pinion Spline Socket T94P-7025-EH to the input shaft. Rotate input shaft back and forth approximately 20 times to seat input shaft tapered roller bearings.

Dial Indicator Installation For Input Shaft Endplay Measurement:

22. With 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 dial indicator to zero.





23. Measure input shaft end-play by lifting input shaft using a lever through the control select lever cover opening. Record a dial indicator reading with the input shaft in the full-up position. Repeat this procedure at least three times, recording each measurement. Calculate an average value by adding the readings and dividing by the number of readings. Record this average value.

Output Shaft Endplay Measurement Tool Installation:

24. Measure output shaft end-play by installing Dial Indicator TOOL-4201-C or equivalent to the transaxle case as shown. Position stem of the dial indicator to plunger arm of Measuring Fixture T94P-4451-AH. Zero dial indicator.





25. Seat output shaft tapered roller bearings by rotating the input shaft (which turns the output shaft) back and forth at least 20 times using Pinion Spline Socket T94P-7025-EH.





26. Use a lever to lift output shaft. Record a dial indicator reading with the output shaft in the full-up position. Repeat this procedure at least three times, recording each measurement. Calculate an average value by adding the readings and dividing by the number of readings. Record this average value.

Shim Selection Tool Adapter Installation:

27. Install Shim Selection Tool Adapter T94P-445 1-BH to outside of the transaxle case using two long bolts as shown.

Dial Indicator And Bracket Installation For Differential Endplay Measurement:

28. Seat differential tapered roller bearings by using Pinion Spline Socket T94P-7025-EH to turn the input shaft back and forth at least 20 times, while pressing down on differential assembly. Install a Dial Indicator With Bracketry TOOL-4201-C or equivalent so that the stem rests on the end of the differential assembly. Zero dial indicator.

Differential Manipulation For Endplay Measurement:

29. Use a 1/2-inch breaker bar to actuate the Measuring Fixture T94P-4451-BH and lift differential assembly. Measure differential assembly end-play by recording a dial indicator reading with the differential assembly in the full up position. Repeat this procedure at least three times, recording each measurement. Calculate an average value by adding the readings and dividing by the number of readings. Record this average value.

Preload Shim Selection Chart:

30. Calculate the required shim thickness readings just taken using the chart. Add the totals of the service shim thickness, average value, and specified preload value. The service shim value and specified preload value are preset.
31. Choose the required shim for each component. Only one shim can be chosen per component. If your required shim value will not match the shim range, lower your required shim value to the next lowest value. Do not raise the required shim value, as doing this can cause damage to internal transaxle components.
32. Remove the clutch side case bearing races and service shims.





33. Using the heating and cooling procedure. Install the correct pre-load shims and bearing races.
34. Lubricate input shaft, output shaft and differential gears and bearings with clean Motorcraft MERCON(r) Multi-Purpose Automatic Transmission Fluid or equivalent meeting MERCON(r) specification.

Input And Output Shaft Alignment:

35. Fit input shaft and output shaft together as shown. Lower both shafts into the transaxle case as an assembly. Seat bearings into their races.





36. Swing input shaft to one side and insert reverse idler gear assembly.





37. Install lower reverse idler gear thrust washer to the transaxle case. Index the tab on the thrust washer to the slot in the housing as shown.

Reverse Idler Gear Assembly Components:

38. Install reverse idler gear bearing and reverse idler gear to the reverse idler gear shaft.
39. Use petroleum jelly to attach the upper reverse idler gear thrust washer to the reverse idler gear shaft support bracket, indexing the tab on the washer with the slot on the bracket.





40. With input and output shafts moved to one side, install the reverse idler gear shaft support bracket. Install two retaining bolts and tighten to 38-51 Nm (28-38 ft. lbs.).





41. Make sure 4th gear synchronizer selector ring is in the neutral position. Install the 5th/reverse gear selector fork and swivel it to one side.





42. Install the 3rd/4th gear selector fork.
43. Install 1st/2nd gear selector fork onto long selector fork rail. Engage 1st/2nd gear selector fork to the synchronizer shifter ring while installing LONG selector fork rail through the 5th/reverse gear selector fork and into its recess in the bottom of the transaxle case.





44. Install short shift fork rail through the 3rd/4th gear selector fork and into its recess in the bottom of the transaxle case. When installed correctly, shift fork rods are the same height.





45. Lubricate differential assembly gear and bearings with clean Motorcraft MERCON(r) Multi-Purpose Automatic Transmission Fluid or equivalent meeting MERCON(r) specification. Install the differential assembly to the transaxle case. Install the magnet into its recess in the case as shown.





46. Clean and dry transaxle housing sealing face. Apply a 0.3 mm (0.008 inch) bead of Gasket Eliminator E1FZ-19562-A or equivalent meeting Ford specification WSK-M2G348-A4 to transaxle case sealing face as shown.





47. Install clutch side transaxle case to gear side transaxle case, engaging the input shaft, output shaft and differential bearings with their races. Install the 16 transaxle case retaining bolts.

NOTE: Transaxle case retaining bolts must be tightened to specification within 15 minutes of sealer application.





48. Clean and dry the transaxle case sealing surface where the control select lever cover is to be installed. Apply a 0.3 mm (0.008 inch) bead of Gasket Eliminator E1FZ-19562-A or equivalent meeting Ford specification WSK-M2G348-A4. Install the control select lever cover to the transaxle case. Install the control select lever cover retaining bolts. Tighten bolts to 11 Nm (8 ft. lbs.) in an alternate pattern.





49. Install speedometer drive bearing and speedometer driven gear assembly to the clutch housing. Install the roll pin with a soft drift and hammer until it is flush with the case.





50. Install the LH and RH differential oil seals using Differential Driveshaft Seal Replacer T94P-7025-CH with Driver Handle T80T-4000-W.
51. Install a new O-ring to the input shaft guide sleeve. Install guide shield to the clutch housing. Tighten three retaining screws to 9 Nm (79 inch lbs.).

Clutch Slave Cylinder Components:

52. Install clutch slave cylinder to the clutch housing by sliding it down over the input shaft. Install the hydraulic pressure line and bleeder pipe. Tighten clutch slave cylinder mounting bolts to 10 Nm (88 inch lbs.). Tighten hydraulic pressure line and bleeder pipe fittings to 14 Nm (124 inch lbs.).