Special Tool(s)

WARNING: This page is about a different car, the 2010 Mercury Milan and 2010 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

SPECIAL TOOL SPECIFICATION TABLE

Courtesy of FORD MOTOR CO.	Holding Fixture 307-003 (T57L-500-B)
Courtesy of FORD MOTOR CO.	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: Identifying Transaxle And 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 Fork & Diaphragm
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
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 & 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: Identifying Transaxle Case Cover Bolts
Courtesy of FORD MOTOR CO.
Remove and discard the 5th/6th gear shift fork roll pin.

Fig 7: Locating Discard 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.
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: Do not reuse locknuts.

Fig 9: Identifying Primary & Secondary Shaft Locknuts
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 10: Identifying Bearing & 6th Gear
Courtesy of FORD MOTOR CO.
Using a suitable tool, remove the bearing and 6th gear from the primary 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: Identifying Bearing & 6th Gear
Courtesy of FORD MOTOR CO.
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
Courtesy of FORD MOTOR CO.
Remove the spacer and the gear sleeve.

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

Fig 15: Locating 5th Speed Primary & 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 & 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 Bolt & 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 & 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 & 4th Gears
Courtesy of FORD MOTOR CO.
Remove the reverse idler gear assembly and shift fork.

Fig 25: Locating Reverse Idler Gear Assembly & Shift Fork
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 & Shift Forks
Courtesy of FORD MOTOR CO.
Remove the primary and secondary shafts at the same time.

Fig 27: Locating Primary & 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 Disassembly and Assembly .