Disassembly
DISASSEMBLE1. Mount transaxle into bench mounting fixture tool No. T57L-500-B, or equivalent.
2. Remove drain plug and drain any remaining fluid from transaxle. Shift to first or second gear, then position transaxle with input shaft down and rear cover facing up.
Capri W/non-turbo Engine:
Exploded View Of Transmission, Capri W/turbo & 92-94 Escort/Tracer:
Exploded View Of Transaxle, 95/96 Escort/Tracer (Part 1 Of 2):
Exploded View Of Transaxle, 95/96 Escort/Tracer (Part 2 Of 2):
3. Remove bolts attaching rear cover to transaxle case.
4. Tap cover with rubber mallet to loosen gasket cover, then remove rear cover.
5. On Capri models with nonturbocharged engine, proceed as follows:
a. Measure fifth gear thrust clearance with dial indicator. Correct clearance is 0.0024-0.0122 inch.
b. If clearance is too great, check contact surfaces of fifth gear and clutch hub. Replace worn or damaged parts.
Input Shaft Locking Tool:
6. On all models, bend down tang on stop plate or lock washer, below fifth gear locknut. Lock input shaft with torque adapter tool No. T87C-7025-A, or equivalent.
7. Remove locknuts and stop plate. Discard locknuts. Apply even pressure and gradually increase to remove locknuts. Do not strike or apply severe shocks to loosen nuts.
8. Drive out roll pin and remove fifth gear shift fork with clutch hub assembly.
9. Remove synchronizer ring, fifth gear and gear sleeve as an assembly by sliding off of shift rod.
10. Lock input shaft as described in preceding steps, then remove locknut on input shaft gear.
11. Remove input gear by sliding off of shaft.
Lock Bolt And Guide Bolt Locations:
12. Remove lock bolt, guide bolt and washer, park/neutral position switch and back-up lamp switch from side of transaxle case.
13. Remove all transaxle housing to clutch housing bolts. Note bolt locations and sizes for installation.
14. Tap transaxle case lightly with a soft mallet to loosen gasket seal, then remove case by sliding it straight up from clutch housing.
15. On models equipped with nonturbocharged engine, proceed as follows:
a. Remove magnet from bottom of clutch housing, then remove reverse idler shaft and gear.
b. Remove roll pin from crank lever shaft.
c. Remove crank lever shaft, crank lever assembly and 0-ring. Discard 0-ring.
d. Remove shift relay bolt from fifth gear shift rod end, then remove rod end.
Shift Rod Assembly Removal, Capri W/non-turbo & Escort/Tracer:
e. Insert pin punch or suitable rod into shift rod roll pin hole. Pull out the shift rod assembly while turning pin punch or rod.
Interlock Sleeve And Control Lever. Capri W/non-turbo & Escort/Tracer:
f. Align interlock sleeve ends and control lever, then turn shift rod counterclockwise.
g. Remove two breather cover bolts, then the cover and gasket.
16. On models equipped with turbo-charged engine, proceed as follows:
a. Insert pin punch or suitable rod into the roll pin hole of the shift rod.
b. Pull out shift rod while turning pin punch or rod.
c. Position interlock sleeve and control lever.
d. Move change rod to turn control rod counterclockwise, then hold change rod in turned position and push inward to raise control rod upward.
e. Remove roll pin with pin punch.
17. On all models, lift out main shaft, input shaft and shift rail as an assembly.
18. On models equipped with non-turbocharged engine, note that steel ball will fall into clutch housing.
19. On models equipped with turbo-charged engine, perform the following:
Control End, Ball, And Spring Removal, (Capri W/turbo):
a. Pull change rod rearward, and remove control end, ball and spring. Use caution not to lose the ball and spring.
b. Turn lever with screwdriver while pushing lever out of housing, then remove input gear shaft front bearing race using puller tool No. T77F-1102-A, or equivalent.
c. Remove main shaft front bearing race by pulling up on oil seal.
20. On models equipped with non-turbocharged engine, perform the following:
a. Separate shift rod and shift fork assembly from each of the clutch hub sleeves, then remove steel ball from clutch housing.
b. With soft hammer, drive out reverse lever shaft and blind plug.
c. Remove spring from reverse lever shaft and remove differential assembly.
21. On models equipped with turbo-charged engine, remove clutch housing components as follows:
a. Remove three bolts, washers, and spacer sleeve securing guide plate to clutch housing, then the guide plate.
b. Loosen and remove change arm bolt and washer, then slide change rod out of clutch housing far enough to remove change arm from rod.
c. Remove roll pin securing selector to change rod by matching pin's position with removing groove, then tapping pin out using suitable drift and hammer.
d. Slide change rod out of clutch housing, then remove boot from oil seal.
e. Retrieve change arm spring, selector and reverse gate from clutch housing.
f. Remove change rod oil seal from clutch housing, then remove breather cover screws and breather cover.
g. Remove the breather from case by turning and pulling out.
22. On 1992-94 models, remove speedometer drive gear assembly from case.
23. On all models, remove reverse lever shaft roll pin, then drive reverse lever shaft out of case.
24. Retrieve reverse lever and lever set spring from case.
25. Remove bearing races, if necessary, as follows:
a. Remove differential front bearing race from clutch housing using bearing puller tool No. T86P-70043-A, puller tool No. T58L-101-B and slide hammer tool No. T50T-100-A, or equivalents.
b. Remove input shaft rear bearing race from transaxle case using bearing puller tool No. T77F-1102-A and slide hammer tool No. T5OT-100-A, or equivalents.
c. Remove diaphragm spring and adjusting shim. Note original position for assembly reference.
d. Remove differential rear bearing race adjusting shim.
e. Remove left and right differential oil seals from transaxle case using bearing puller tool No. T77F-1102-A and slide hammer tool No. T5OT-100-A, or equivalents.
f. Remove main shaft rear bearing race from transaxle case using bearing puller tool No. T77F-1102-A and slide hammer tool No. T50T-100-A, or equivalents.
26. Remove control selector plate, selector arm bolt and input shift shaft selector plate arm; then, using a suitable pin punch remove and discard selector pin.
27. Remove input shift shaft and gearshift control shaft boot, then the spring.
28. Remove shift gate selector; then, using collet tool No. D80L-100-Q, actuator pin tool No. D80L-100-G and slide hammer tool No. D80L-100-D, or equivalents, remove shifter shaft seal.
29. On 1995-96 models, remove breather and vehicle speed sensor.