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Manual Transmission/Transaxle - Transaxle—Vehicles Built From: 07/2000 Fiesta 1996 (08/1995-02/2002)
Disassembly

Special Tool(s)

Remover, Drive Pinion Seal

205-078 (15-048)

Remover, Differential Bearing Cone

205-176 (15-074)

Mounting Bracket, Engine/Differential

205-329 (15-105A)

Remover, Seal

303-112 (21-051)

Separator, oil pan

303-428 (21-179)

Mounting Stand

303-435 (21-187)

Mounting Bracket for 303-435

303-435-06 (21-031B)

Installer, Extension Housing Bushing/Seal

308-045 (16-015)

Remover, Input Shaft Fifth Gear

308-082 (16-035)

General Equipment
Blanking plugs
Drift

Disassembly

CAUTION:
CAUTION:Use vise protectors.
CAUTION:
CAUTION:Use a copper or plastic mallet to prevent damage.

  1. Using the special tools, mount the transaxle on the mounting stand.
  1. Clean any grease and foreign material from the input shaft.

  1. Remove the clutch slave cylinder.

  1. Remove the vehicle speed sensor (VSS).
    1. Remove the retaining pin.
    1. Pull out the VSS.

  1. Remove the selector interlock mechanism.

  1. Remove the fifth gear housing cover retaining bolts.

  1. Using the special tool, remove the fifth gear housing cover.

  1. Remove the fifth gear synchronizer assembly, the selector fork and the fifth gear.
    1. Remove and discard the snap ring.
    1. Remove and discard the retaining pin.

  1. NOTE:
    NOTE:To aid assembly mark the position of the fifth gear synchronizer assembly.
    Disassemble the fifth gear and synchronizer assembly.
    1. Snap-ring.
    1. Retaining plate.
    1. Synchronizer assembly.
    1. Synchronizer ring.
    1. Fifth gear.

  1. Remove the fifth gear snap ring.
    • Discard the snap ring.

  1. Using the special tool, remove the fifth gear.

  1. Remove the fifth gear housing.
    • Discard the bolts.

  1. Remove the fifth gear housing gasket, the snap rings and the blanking plug.
    1. Remove and discard the gasket.
    1. Remove the output shaft snap ring.
    1. Remove the input shaft snap ring.
    1. Pull out the blanking plug.

  1. Using the special tool, remove both halfshaft oil seals (left-hand side shown).
    • Only remove the reversing lamp switch if there is evidence of leakage.

  1. Separate the two halves of the transaxle housing (14 bolts).
    • Carefully separate the transaxle housing.

  1. Remove the selector shaft guide sleeve upper snap ring.
    1. Remove and discard the upper snap ring.
    1. Slide the selector shaft guide sleeve downwards.

  1. Remove the selector shaft guide sleeve.
    1. Remove and discard the selector shaft guide sleeve lower snap ring.
    1. Remove the selector shaft guide sleeve.

  1. NOTE:
    NOTE:Install a rubber band to the second selector shaft to aid assembly.
    Remove the input shaft, the output shaft and the selector forks as an assembly.

  1. Remove the reverse gear idler, the selector shaft and the shift lock.
    1. Remove the reverse gear idler.
    1. Remove the selector shaft and the shift lock.

  1. Using a suitable drift, remove and discard the input shaft oil seal.

  1. Remove the differential assembly and the permanent magnet.

  1. Remove the output shaft roller bearing.
    • Remove the rollers and the roller cage from the output shaft roller bearing.

  1. CAUTION:
    CAUTION:Only use the special tool as shown, failure to do so may result in the blanking plug being pressed out of the housing.
    Using the special tool, remove the output shaft roller bearing outer race.
    • Remove the oil funnel.

  1. Using the special tool, remove the differential bearing cup.

  1. NOTE:
    NOTE:Install the special tool in the transaxle housing grooves.
    Using the special tool, remove the differential bearing cup.

Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer Case > 308-03 Manual Transmission-Transaxle > Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Removal > Disassembly > Transaxle - Vehicles Built From: 07-2000

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