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Special Tool(s)

WARNING: This page is about a different car, the 2002 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Special Tool(s) (1 Of 2)
G02051203Courtesy of FORD MOTOR CO.
Fig 2: Special Tool(s) (2 Of 2)
G02051204Courtesy of FORD MOTOR CO.
Fig 3: Exploded View Of Transaxle
G02051205Courtesy of FORD MOTOR CO.
  1. Clean the transaxle exterior with solvent before disassembly.
  2. Clean all removed parts (except sealed bearings) and all sealing surfaces with solvent, and dry with compressed air.
    3. WARNING: Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes. Wear protective eye wear whenever using compressed air. Failure to follow these instructions may result in personal injury.
  3. Clean out all holes and passages with compressed air and verify that there are no obstructions.
  4. Using the special tool, mount the transaxle to a bench.
    Fig 4: Mounting Transaxle To A Bench Using Special Tool
    G02051206Courtesy of FORD MOTOR CO.
  5. Remove the clutch release fork and bearing.
    1. Remove the boot.
    2. Remove the clutch release fork and bearing.
    Fig 5: Removing Clutch Release Fork And Bearing
    G02051207Courtesy of FORD MOTOR CO.
  6. Remove the anchor bolt.
    Fig 6: Removing Anchor Bolt
    G02051208Courtesy of FORD MOTOR CO.
  7. Remove the park/neutral position (PNP) switch.
    Fig 7: Removing Park/Neutral Position Switch
    G02051209Courtesy of FORD MOTOR CO.
  8. Remove the bolt and the vehicle speed sensor (VSS).
    Fig 8: Removing Bolt And Vehicle Speed Sensor
    G02051210Courtesy of FORD MOTOR CO.
  9. Rotate the transaxle 180 degrees.
  10. Remove the reversing lamp switch.
    Fig 9: Removing Reversing Lamp Switch
    G02051211Courtesy of FORD MOTOR CO.
  11. Remove the clutch slave cylinder line bracket.
    1. Remove the bolts.
    2. Remove the clutch slave cylinder line bracket.
    Fig 10: Removing Clutch Slave Cylinder Line Bracket
    G02051212Courtesy of FORD MOTOR CO.
  12. Shift the transaxle into first gear.
  13. Remove the case cover.
    1. Remove the bolts.
    2. Remove the case cover.
    Fig 11: Removing Case Cover
    G02051213Courtesy of FORD MOTOR CO.
    14. CAUTION: Do not  reuse locknuts.
    Fig 12: Removing Input And Output Shaft Locknuts
    G02051214Courtesy of FORD MOTOR CO.
  14. Remove the input and output shaft locknuts and discard.
    1. Using the special tool, keep the input shaft from turning.
    2. Remove the input and output shaft locknuts and discard.
  15. Remove the reverse synchronizer blocking ring retainer assembly.
    1. Remove the spacer.
    2. Remove the reverse synchronizer blocking ring retainer assembly.
    Fig 13: Removing Input And Output Shaft Locknuts
    G02051215Courtesy of FORD MOTOR CO.
    16. CAUTION: The synchronizer blocking rings are not interchangeable. Make sure to keep them in the order that they were removed.
    Fig 14: Removing Reverse Synchronizer Blocking Ring
    G02051216Courtesy of FORD MOTOR CO.
  16. Remove the reverse synchronizer blocking ring.
  17. Remove and discard the reverse/fifth shift fork roll pin.
    Fig 15: Removing Reverse/Fifth Shift Fork Roll Pin
    G02051217Courtesy of FORD MOTOR CO.
  18. Remove the reverse/fifth shift fork and synchronizer hub assembly.
    Fig 16: Removing Reverse/Fifth Shift Fork And Synchronizer Hub Assembly
    G02051218Courtesy of FORD MOTOR CO.
  19. Remove the synchronizer blocking ring.
    Fig 17: Removing Synchronizer Blocking Ring
    G02051219Courtesy of FORD MOTOR CO.
  20. Remove the fifth speed cluster gear.
    Fig 18: Removing Fifth Speed Cluster Gear
    G02051220Courtesy of FORD MOTOR CO.
  21. Remove the fifth gear bushing.
    Fig 19: Removing Fifth Gear Bushing
    G02051221Courtesy of FORD MOTOR CO.
  22. Remove the fifth gear spacer and fifth speed gear.
    1. Remove the fifth gear spacer.
    2. Remove the fifth speed gear.
    Fig 20: Removing Fifth Gear Spacer And Fifth Speed Gear
    G02051222Courtesy of FORD MOTOR CO.
  23. Remove the reverse idler shaft lock bolt and shift rail guide bolt.
    Fig 21: Removing Reverse Idler Shaft Lock Bolt
    G02051223Courtesy of FORD MOTOR CO.
  24. Remove the bolt, spring, and ball.
    Fig 22: Removing Bolt, Spring, And Ball
    G02051224Courtesy of FORD MOTOR CO.
  25. Separate the transaxle case.
    1. Remove the 15 transaxle case bolts.
    2. Separate the transaxle case.
    Fig 23: Separating Transaxle Case
    G02051225Courtesy of FORD MOTOR CO.
  26. Remove the magnet.
    Fig 24: Removing Magnet
    G02051226Courtesy of FORD MOTOR CO.
  27. Remove the reverse idler gear.
    1. Remove the reverse idler gear shaft.
    2. Remove the reverse idler gear.
    Fig 25: Removing Reverse Idler Gear
    G02051227Courtesy of FORD MOTOR CO.
  28. Remove the shift gate bolt.
    Fig 26: Removing Shift Gate Bolt
    G02051228Courtesy of FORD MOTOR CO.
  29. Remove the shift control shaft and shift gate.
    1. Remove the shift control shaft.
    2. Remove the shift gate.
    Fig 27: Removing Shift Control Shaft And Shift Gate
    G02051229Courtesy of FORD MOTOR CO.
  30. Remove the shift lever shaft roll pin.
    Fig 28: Removing Shift Lever Shaft Roll Pin
    G02051230Courtesy of FORD MOTOR CO.
  31. Remove the shift lever shaft and shift fork selector lever.
    1. Remove the shift lever shaft.
    2. Remove the shift fork selector lever.
    Fig 29: Removing Shift Lever Shaft And Shift Fork Selector Lever
    G02051231Courtesy of FORD MOTOR CO.
  32. Shift into second and fourth gears.
    33. WARNING: When removing the gear shifter fork and main shift control shaft assembly the detent ball will fly out. Hold a shop towel over the detent ball and spring to prevent the ball from becoming airborne. Failure to follow these instructions may result in personal injury.
    Fig 30: Removing Gear Shifter Fork And Main Shift Control Shaft Assembly
    G02051232Courtesy of FORD MOTOR CO.
  33. Remove the gear shifter fork and main shift control shaft assembly, detent ball and spring.
  34. Remove the output and input shafts as an assembly.
    Fig 31: Removing Output And Input Shafts
    G02051233Courtesy of FORD MOTOR CO.
  35. Remove the differential.
    Fig 32: Removing Differential
    G02051234Courtesy of FORD MOTOR CO.
    36. NOTE: Flywheel housing side shown, transaxle case side similar.
    Fig 33: Removing Input Shaft Bearing Cups
    G02051235Courtesy of FORD MOTOR CO.
  36. Remove the input shaft bearing cups.
  37. Using the special tools, remove the input shaft seal.
    Fig 34: Removing Input Shaft Seal Using Special Tools
    G02051236Courtesy of FORD MOTOR CO.
    38. NOTE: Flywheel housing side shown, transaxle case side similar.
    Fig 35: Removing Output Shaft Bearing Cups
    G02051237Courtesy of FORD MOTOR CO.
  38. Remove the output shaft bearing cups.
  39. Remove the funnel.
    Fig 36: Removing Funnel
    G02051238Courtesy of FORD MOTOR CO.
  40. Remove the shift control selector plate and spacer.
    1. Remove the bolts.
    2. Remove the shift control selector plate and spacer.
    Fig 37: Removing Shift Control Selector Plate And Spacer
    G02051239Courtesy of FORD MOTOR CO.
  41. Remove the shift control shaft selector lever.
    1. Remove the bolt.
    2. Remove the shift control shaft selector lever.
    Fig 38: Removing Shift Control Shaft Selector Lever
    G02051240Courtesy of FORD MOTOR CO.
  42. Remove and discard the roll pin.
    Fig 39: Removing Roll Pin
    G02051241Courtesy of FORD MOTOR CO.
  43. Remove the shift control shaft assembly.
    Fig 40: Removing Shift Control Shaft Assembly
    G02051242Courtesy of FORD MOTOR CO.
  44. Using the special tool, remove the shift control shaft seal.
    Fig 41: Removing Shift Control Shaft Seal Using Special Tool
    G02051243Courtesy of FORD MOTOR CO.
  45. Remove the vent tube.
    1. Remove the bolts.
    2. Remove the vent tube.
    Fig 42: Removing Vent Tube
    G02051244Courtesy of FORD MOTOR CO.
    46. NOTE: Flywheel housing side shown, transaxle case side similar.
    Fig 43: Removing Differential Bearing Cups Using Special Tools
    G02051245Courtesy of FORD MOTOR CO.
  46. Using the special tools, remove the differential bearing cups.
  47. Remove and discard the reverse lever roll pin.
    Fig 44: Removing Reverse Lever Roll Pin
    G02051246Courtesy of FORD MOTOR CO.
  48. Remove the reverse lever shaft.
    1. Remove the reverse lever shaft.
    2. Remove the reverse lever.
    Fig 45: Removing Reverse Lever
    G02051247Courtesy of FORD MOTOR CO.
    49. NOTE: Transaxle case side shown, flywheel housing side similar.
    Fig 46: Removing Halfshaft Seals Using Special Tool
    G02051248Courtesy of FORD MOTOR CO.
  49. Using the special tool, remove the halfshaft seals.
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