Special Tool(s)

WARNING: This page is about a different car, the 2011 Mercury Milan and 2011 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

	Holding Fixture 307-003 (T57L-500-B)
	Turning Torque Socket, Transmission 308-160 (T88C-7025-GH)

NOTE: Clean the transaxle exterior before disassembly.

NOTE: Clean all removed parts and all sealing surfaces with solvent, and dry with compressed air.

NOTE: Clean out all holes and passages with compressed air and verify that there are no obstructions.

Mount the transaxle to the Holding Fixture.

Fig 1: Mounting Transaxle To Holding Fixture
Courtesy of FORD MOTOR CO.
Remove the clutch release fork and bearing.
NOTE: May need to use a screwdriver to pry the clutch release fork off the anchor bolt, if needed.
1. Remove the clutch release bearing.
2. Remove the clutch release fork and diaphragm.
  
  Fig 2: Identifying Clutch Release Bearing And Clutch Release Fork
  Courtesy of FORD MOTOR CO.
If necessary, remove the anchor bolt.

Fig 3: Locating Anchor Bolt
Courtesy of FORD MOTOR CO.
Remove the bolt and the Vehicle Speed Sensor (VSS).

Fig 4: Locating Vehicle Speed Sensor And Bolt
Courtesy of FORD MOTOR CO.
Remove the reversing lamp switch wiring harness retainer bolt and reversing lamp switch.

Fig 5: Locating Reversing Lamp Switch Wiring Harness Retainer Bolt And Reversing Lamp Switch
Courtesy of FORD MOTOR CO.
Shift the transaxle into the NEUTRAL position.
Remove the 9 case cover bolts and the case cover.

Fig 6: Locating Case Cover And Mounting Bolts
Courtesy of FORD MOTOR CO.
Remove and discard the 5th/6th gear shift fork roll pin.

Fig 7: Locating 5th/6th Gear Shift Fork Roll Pin
Courtesy of FORD MOTOR CO.
Shift the 5th/6th gear shift fork to 5th.

Fig 8: Locating 5th/6th Gear Shift Fork
Courtesy of FORD MOTOR CO.

NOTE: Do not reuse locknuts.

Fig 9: Identifying Locking Tabs

Courtesy of FORD MOTOR CO.

Remove the primary and secondary shaft locknuts.
1. Using the Transmission Turning Torque Socket, keep the input shaft from turning.
2. Using a punch, release the locking tabs from the shafts. Remove and discard the primary and secondary shaft locknuts.

NOTE: Make sure the tabs of the suitable tool are securely positioned on the gear or damage to the gear may occur.

Fig 10: Removing Bearing And 6th Gear From Secondary Shaft

Courtesy of FORD MOTOR CO.

Using a suitable tool, remove the bearing and 6th gear from the secondary shaft.

NOTE: Make sure the tabs of the suitable tool are securely positioned on the gear or damage to the gear may occur.

Fig 11: Removing Bearing And 6th Gear From Primary Shaft

Courtesy of FORD MOTOR CO.

Using a suitable tool, remove the bearing and 6th gear from the primary shaft.
Remove the gear sleeve.

Fig 12: Locating Gear Sleeve
Courtesy of FORD MOTOR CO.
Remove the 5th/6th shift fork and synchronizer assembly.

Fig 13: Locating 5th/6th Shift Fork And Synchronizer Assembly
Courtesy of FORD MOTOR CO.
Remove the spacer and the gear sleeve.

Fig 14: Locating Spacer And Gear Sleeve
Courtesy of FORD MOTOR CO.
Remove the 5th speed primary and secondary gears.

Fig 15: Locating 5th Speed Primary And Secondary Gears
Courtesy of FORD MOTOR CO.

NOTE: Make sure the transaxle is in neutral.
Remove the reverse idler shaft lock bolt and shift rail guide bolt.

Fig 16: Locating Reverse Idler Shaft Lock Bolt And Shift Rail Guide Bolt
Courtesy of FORD MOTOR CO.
Remove the shift detent bolt, spring and ball.

Fig 17: Locating Shift Detent Bolt
Courtesy of FORD MOTOR CO.
Remove the 15 transaxle case bolts and separate the transaxle case.
- After separating the transaxle cases, position the removed case on its side. Use care not to damage the funnel.
Fig 18: Locating Transaxle Case Bolts
Courtesy of FORD MOTOR CO.
Remove the funnel bolt and the funnel.

Fig 19: Locating Funnel
Courtesy of FORD MOTOR CO.
Remove the magnet.

Fig 20: Locating Magnet
Courtesy of FORD MOTOR CO.
Remove the shift lever shaft pin, then remove the shift lever shaft and shift fork selector lever.

Fig 21: Locating Shift Lever Shaft Pin, Shift Lever Shaft And Shift Fork Selector Lever
Courtesy of FORD MOTOR CO.
Remove the shift gate bolt.

Fig 22: Locating Shift Gate Bolt
Courtesy of FORD MOTOR CO.
Remove the shift control shaft and remove the shift gate.

Fig 23: Locating Shift Control Shaft
Courtesy of FORD MOTOR CO.
Move the shift forks upward into 2nd and 4th gears.

Fig 24: Moving Shift Forks Upward Into 2nd And 4th Gears
Courtesy of FORD MOTOR CO.
Remove the reverse idler gear assembly and shift fork.

Fig 25: Locating Reverse Idler Gear Assembly
Courtesy of FORD MOTOR CO.
Rotate the main shift control shaft clockwise to free the interlock from the 1-2 and 3-4 shift forks.
Raise the main shift control shaft until it clears the bore in the transaxle case and remove the main shift control shaft assembly, shift forks.

Fig 26: Locating Main Shift Control Shaft Assembly And Shift Forks
Courtesy of FORD MOTOR CO.
Remove the primary and secondary shafts at the same time.

Fig 27: Locating Primary And Secondary Shafts
Courtesy of FORD MOTOR CO.
Remove the differential.

Fig 28: Locating Differential
Courtesy of FORD MOTOR CO.
For further disassembly of the transaxle case, refer to TRANSAXLE CASE in this service information.