Part 1

Special Tools:

NOTE: Whenever the transaxle has been disassembled, the bearing preload must be adjusted. The input shaft, output shaft and differential bearing preload can be adjusted by selecting shims to insert between the bearing races and the case on the case side.

1. Install the input shaft bearing cup into the flywheel housing.

2. Install the input shaft.

3. Position the bearing cup onto the bearing, then install Shim Selection Gauge on the bearing cup.

4. Position collars onto the flywheel housing.

5. Position the transaxle case on collars and install the bolts.

6. Mount Dial Indicator and Dial Indicator Bracketry on the transaxle case.
7. Rotate the input shaft to seat the bearings.

8. Zero Dial Indicator.

9. Rotate the input shaft until Dial Indicator returns to zero. Raise the input shaft and read the end play.

CAUTION: The shaft must be lifted equally on both sides or it may cock to one side, resulting in an incorrect reading.

10. Repeat the previous step to obtain three readings within 0.10 mm (0.004 inch) of each other. Use the formula shown to select the correct shim size.
11. From Shim Selection Kit meeting Ford specification, select the shim(s) that is closest to (or slightly thinner than) the final shim size determined in the previous step.

NOTE: Do not use more than two shims.

12. Remove the transaxle case, gauge, bearing cup, and input shaft.

13. Install the shim.

14. Use (A) Driver Handle and (B) Bearing Cup Replacer to install the (C) input shaft bearing cup.

15. Install the fifth shaft funnel and the output shaft bearing cup.
1 Install the fifth shaft funnel.
2 Install the output shaft bearing cup.

16. Install the output shaft.

17. Position the bearing cup onto the bearing.

18. Position Shim Selection Gauge on the bearing cup.

NOTE: The gauge halves must be turned to eliminate any gap between them.

19. Position collars onto the flywheel housing.

20. Position the transaxle case on collars and install the bolts.

21. Mount Dial Indicator and Dial Indicator Bracketry on the transaxle case.
22. Rotate the output shaft to seat the bearings.

23. Zero Dial Indicator.

24. Rotate the output shaft until Dial Indicator returns to zero. Raise the output shaft and read the end play.

CAUTION: The shaft must be lifted equally on both sides or it may cock to one side, resulting in an incorrect reading.

25. Repeat the previous step to obtain three readings within 0.10 mm (0.004 inch) of each other. Use the formula shown to select the correct shim size.
26. From Shim Selection Kit meeting Ford specification, select the shim(s) that is closest to (or slightly thinner than) the final shim size determined in the previous step.

NOTE: Do not use more than two shims.

27. Remove the transaxle case, gauge, bearing cup and output shaft.

28. Install the shim.

29. Use (A) Driver Handle and (B) Bearing Cup Replacer to install the (C) output shaft bearing cup.

30. Use (A) Differential Bearing Cone Replacer and (B) Driver Handle to install the (C) differential bearing cup into the flywheel housing.

31. Install the differential.

32. Position the bearing cup onto the bearing.

33. Place Shim Selection Gauge onto the bearing cup.

NOTE: The gauge halves must be turned to eliminate any gap between them.

34. Position collars on the flywheel housing.

35. Position the transaxle case on collars and install the bolts.

36. Use (A) pins to adjust (B) Shim Selection Gauge until the free play is removed. Turn Shim Selection Gauge back together.

37. Insert Differential Rotator through the transaxle case and engage the differential pinion shaft.

38. Use pins to adjust Shim Selection Gauge until the differential rotation is within specification.

39. Use a feeler gauge to measure the gap in Shim Selection Gauge.
40. Add 0.15 mm (0.0059 inch) to the feeler gauge measurement to achieve the final clearance.

41. Use the chart shown to select the differential bearing shims that are closest to (or slightly larger than) the value obtained in Step 40.

NOTE: Do not use more than two differential shims.

42. Remove the transaxle case, gauge, bearing cup, and differential.

43. Install the differential shim(s) into the transaxle case.

44. Use (A) Differential Bearing Cone Replacer and (B) Driver Handle to install the differential bearing cup into the (C) transaxle case.