Assembly

Special Tools:

1. Clean and check all parts carefully before assembly.
- All sliding parts should be lubricated with Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or equivalent meeting MERCON specification.

CAUTION: Bearing races require a heating and cooling procedure and special tools for installation. This procedure must be followed to provide accurate preload measurements.

2. Install the reverse gear idler shaft.
1 Apply sealer ESK-M4G269-A to the reverse gear idler shaft plate mating face.
2 Align the reverse gear idler shaft plate using the longer locating bolt and drive it in.
3 Remove the locating bolt and install the original bolts.

NOTE: Heat the transaxle housing to approximately 80° C.

3. Install the bearing race and shims using Driver Handle and Bearing Cup Replacer.
1 Install the input shaft bearing race and a 1.00 mm shim.
2 Install the output shaft bearing race and 1.00 mm shim.
3 Install the differential bearing race and a 1.10 mm shim.

NOTE: Heat the transaxle housing area to approximately 80° C and cool the bearing races.

4. Install the bearing using Driver Handle and the Differential Bearing Cone Replacer.

CAUTION: Do not use the bearing as a support. Support the differential under the gear.

5. Engage the fourth gear synchronizer on the input shaft.

6. Assemble the input and output shafts together and put them in the transaxle case as an assembly.

7. Install the differential assembly.

8. Position the housing and tighten the sixteen flange bolts uniformly.

9. Prepare the input shaft for measuring.
- Turn the input shaft back and forth to to settle the bearings using Pinion Spline Socket.

10. Set up Dial Indicator on the transaxle housing and set it to zero.

11. Measure the input shaft end float.
1 Lift the input shaft with a lever.
2 Note the resulting measurement.

12. Install Measuring Fixture.
1 Position Measuring Fixture.
2 Install the bolts.
3 Position the fixture on the fourth gear.

13. Measure the output shaft end float.
- Set up Dial Indicator and set it to zero.
- Lift the output shaft with a lever and note the resulting measurement.

14. Prepare the differential for measuring.
- Turn the output shaft back and forth using Pinion Spline Socket and at the same time press down.
- Set up Dial Indicator and set it to zero.

15. Measure the differential end float.
- Lift the differential with the Valve Spring Compressor and the Shim Selection Tool Adapter, and note the resulting measurement.
16. Select the correct shim(s) for the differential, input, and output shafts.
17. Remove the bearing cups again.

18. Cool and install the bearing race and required shims using Driver Handle and Bearing Cup Replacer.
1 Install the input bearing race and shim.
2 Install the output shaft bearing race and shim.
3 Install the differential bearing race and shim.

NOTE: Heat the transaxle housing area to approximately 80° C.

19. Assemble the reverse gear idler assembly.
1 Install the lower thrust washer.
2 Install the bearing.
3 Install the reverse gear idler.
4 Install the upper thrust washer.
5 Install the bracket.

NOTE: The reverse gear idler should be installed with the small collar facing downward.

20. Install the reverse gear idler, input and output shafts.
1 Install the input and output shafts together as an assembly.
2 Install the reverse gear idler shaft assembly.
3 Apply sealer ESK-M4G269-A to the threads of the bolts and install them.

21. Install the fifth/reverse gear selector fork and position it to the side.

NOTE: Make sure the fourth gear selector ring is in the neutral position.

22. Install the third/fourth gear selector fork.

23. Install the first/second gear selector fork and rods.

NOTE: When installed correctly, the selector rods are the same height.

24. Install the differential assembly.
1 Install the differential assembly.
2 Install the magnetic disk in the recess.

25. Treat the mating face with sealer.
- The mating face must be dry. Sealer ESK-M4G269-A must be applied in an even coating to the inside of the mating face. (The even bead of sealer should have a diameter of 2 mm).

26. Install the transaxle case.
- Tighten the sixteen flange bolts, working diagonally.

27. Position the selector mechanism and install the bolts.
- Coat the mating face with sealer ESK-M4G269-A.

NOTE: Make sure the transaxle is in neutral (the gearshift lever and selector lever must be vertical).

28. Install the speedometer drive pinion.
1 Install the speedometer drive pinion.
2 Install the roll pin.

29. Install the differential oil seals using Driver Handle and Differential Drive Shaft Seal Replacer.

30. Install the slave cylinder.
1 Install the clutch slave cylinder using a new oil seal and sealer ESK-M4G269-A.
2 Install the hydraulic line and the bleed nipple.