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Transaxle Reassembly

NOTE: Lightly oil all shaft and bearing bores with Mercon ATF prior to assembly.
CAUTION: Input shaft, output shaft and differential bearing races require a heating and cooling procedure and special tools for installation into either case half. Reverse idler gear shaft-to-transaxle case is an interference fit. Transaxle case must be heated before installing shaft. These procedures MUST be followed to prevent premature wear of cases and to provide accurate preload measurements.
  1. Using a heat gun, heat transaxle case in reverse idler shaft mounting area to 176°F (80°C). Lightly apply silicone sealant to mating surface of reverse idler gear shaft retaining plate. Using longer mounting bolt, position idler gear shaft in case. Drive idler gear shaft until retaining plate contacts case. Install mounting bolts and tighten to specification.
    2. NOTE: Preload shims are installed under input shaft, output shaft and differential bearing races in clutch housing side of case. Specific measurement shims supplied in service shim kit are used to determine thickness of shims required for final assembly. Each time bearing races are installed, heating-cooling procedure and special tools must be used.
  2. Cool outer bearing races to at least 46°F (8°C) by placing in freezer for approximately 30 minutes. Heat transaxle case, in output shaft bearing race area, to 176°F (80°C). Install output shaft bearing race. Repeat procedure, installing input shaft and differential bearing races into transaxle case. Press bearing races down.
    3. CAUTION: Shim thickness is critical, ensure proper service shim is installed.
  3. Cool clutch housing bearing races to 46°F (8°C). Heat clutch housing to 176°F (80°C), in area of race to be installed. Install service shim and bearing race. Shim thickness is specified for each component. See PRELOAD SHIM SELECTION  table. Repeat procedure, installing remaining service shims and bearing races into clutch housing.
  4. Install differential bearing. Engage 4th gear on input shaft. Fit input and output shafts together and lower into transaxle case as an assembly. DO NOT lubricate tapered roller bearings. Lower differential assembly into case.
  5. Place clutch housing onto transaxle case. DO NOT apply sealant to case halves. Install transaxle case bolts and tighten to specification in crisscross pattern.
    PRELOAD SHIM SELECTION

    Application Service Shim - In. (mm) Preload - In. (mm)
    Input Shaft (1) .039 (1.00) .002 (.05)
    Output Shaft (2) .039 (1.00) .005 (.13)
    Differential (3) .043 (1.10) .013 (.33)
    (1) Input shaft preload shims are available in thicknesses of .045-.067" (1.15-1.71 mm) in .0004" (.01 mm) increments.
    (2) Output shaft preload shims are available in thicknesses of .056-.075" (1.51-1.91 mm) in .0008" (.02 mm) increments.
    (3) Differential preload shims are available in thicknesses of .055-.087" (1.40-2.20 mm) in .002" (.05 mm) increments.
  6. Using Pinion Spline Socket (T94P-7025-EH), rotate input shaft back and forth approximately 20 times to seat bearings. Mount dial indicator on clutch housing with indicator pointer on end of input shaft. Zero dial indicator. Using pry bar placed through shift control assembly opening, raise input shaft and note dial indicator reading. Repeat at least 3 times and calculate average reading.
  7. Install Measuring Fixture (T94P-4451-AH) to transaxle case at shift control assembly opening. See Fig 2. Position measuring bar on 4th gear face. To measure output shaft end play, mount dial indicator on transaxle case with indicator plunger on arm of measuring fixture. See Fig 3. Zero dial indicator. Rotate input shaft to seat bearings. Using pry bar, raise output shaft and note dial indicator reading. Repeat at least 3 times and calculate average reading.
  8. Install Measuring Fixture (T94P-4451-BH) to outside of transaxle case. See Fig 4. Rotate input shaft, while pressing down on differential to seat bearings. Mount dial indicator on transaxle case with indicator plunger on end of differential assembly. See Fig 5. Zero dial indicator. Using a 1/2" breaker bar to actuate measuring fixture, raise differential assembly and note dial indicator reading. Repeat at least 3 times and calculate average reading.
  9. To calculate required shim dimension, add each average reading just obtained to appropriate service shim and preload dimension. See PRELOAD SHIM SELECTION  table. Select shim that is closest to or slightly smaller than required dimension. Use only one shim for each component. Remove clutch housing. Remove bearing races and service shims.
    Fig 1: Measuring Input Shaft End Play
    G96G04647Courtesy of FORD MOTOR CO.
    Fig 2: Installing Output Shaft End Play Measuring Fixture
    G96E04646Courtesy of FORD MOTOR CO.
    Fig 3: Measuring Output Shaft End Play
    G96I04648Courtesy of FORD MOTOR CO.
    Fig 4: Installing Differential End Play Measuring Fixture
    G96A04649Courtesy of FORD MOTOR CO.
    Fig 5: Measuring Differential End Play
    G96C04650Courtesy of FORD MOTOR CO.
  10. Using heating and cooling procedure in step  3, install correct preload shims and bearing races into clutch housing. Lubricate input shaft, output shaft and differential gears and bearings with Mercon ATF. Move input shaft to one side and install reverse idler gear thrust washer. Ensure thrust washer tab engages slot in case.
  11. Install reverse idler gear with small collar down, then install needle bearing. Using petroleum jelly, attach upper reverse idler gear thrust washer to shaft support bracket. Ensure thrust washer tab engages slot in bracket. See Fig 6. With input and output shafts moved to one side, install reverse idler gear shaft support bracket. Tighten bolts to specification.
  12. Ensure 4th gear synchronizer selector ring is in neutral position. Install 5th-Reverse shift fork and swing to one side. Install 3rd-4th shift fork. Install 1st-2nd shift fork and rods.
  13. When installed correctly, shift fork rails are same height. Lubricate differential assembly gear and bearings. Install differential assembly to transaxle case. Clean and install magnet in pocket of transaxle case.
  14. Clean and dry transaxle case mating surface. Apply a .012" (.30 mm) wide bead of sealer to transaxle case mating surface. See Fig 7. Place clutch housing onto transaxle case. Install transaxle case bolts and tighten in crisscross pattern to specification. Case bolts must be tightened to specification within 15 minutes of sealer application.
  15. Clean and dry transaxle case mating surface where control selector cover is to be installed. Apply a .012" (.30 mm) wide bead of sealer. Install shift control assembly and tighten bolts to specification. Install speedometer driven gear or vehicle speed sensor. Install roll pin flush with case.
  16. Using appropriate seal replacer, install left and right differential oil seals. Install input shaft guide sleeve and NEW "O" ring to clutch housing. Tighten retaining bolts to specification. Slide clutch slave cylinder over input shaft. Install pressure line and bleeder pipe. Tighten retaining bolts and pipe fittings to specification.
Fig 6: Installing Reverse Idler Gear & Support Bracket
G96E04651Courtesy of FORD MOTOR CO.
Fig 7: Sealing Case Halves
G96G04652Courtesy of FORD MOTOR CO.
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