Your Vehicle: 2001 Ford Escort ZX2 L4-2.0L DOHC VIN 3
 
Vehicle » Transmission and Drivetrain » Manual Transmission/Transaxle » Service and Repair » Disassembly  
 
 
  Disassembly  
 

  

Special Tool(s)

  
  

  1. Clean the transaxle exterior with solvent before disassembly.
  2. Clean all removed parts (except sealed bearings) and all sealing surfaces with solvent, and dry with compressed air.
  3. WARNING: Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes. Wear protective eye wear whenever using compressed air.

Clean out all holes and passages with compressed air and verify that there are no obstructions.

  

  1. Mount the transaxle on Bench Mounted Holding Fixture.

  

  1. Remove the case cover.
  1. Remove the bolts.
  2. Remove the case cover.
  1. Shift the transaxle into first gear.

  

  1. CAUTION: Do not reuse locknuts. Use Input Shaft Holder to remove the input and output locknuts. Discard the input and output locknuts.

  

  1. Remove the reverse synchronizer blocking ring retainer assembly.
  1. Remove the spacer.
  2. Remove the reverse synchronizer blocking ring retainer assembly.

  

  1. Remove the reverse synchronizer blocking ring.

  

  1. Remove and discard the reverse/fifth shift fork roll pin.

  

  1. Remove the reverse/fifth shift fork and synchronizer hub assembly.

  

  1. Remove the synchronizer blocking ring.

  

  1. Remove the input shaft fifth gear.

  

  1. Remove the fifth gear bushing.

  

  1. Remove the output shaft fifth gear spacer and fifth gear.
  1. Remove the fifth gear spacer.
  2. Remove the fifth output shaft gear.

  

  1. Remove the reverse idler shaft lock bolt.

  

  1. Remove the shift rail guide bolt.

  

  1. Remove the lock bolt, spring, and ball.

  

  1. Remove the backup lamp switch.

  

  1. Remove the transaxle mount bracket.
  1. Remove the bolts.
  2. Remove the transaxle mount bracket.

  

  1. Separate the transaxle case.
  1. Remove the thirteen transaxle case bolts.
  2. Separate the transaxle case.

  

  1. Remove the magnet.

  

  1. Remove the reverse idler gear.
  1. Remove the reverse idler shaft.
  2. Remove the reverse idler gear.

  

  1. Remove the shift gate bolt.

  

  1. Remove the shift control rod and gate.
  1. Remove the shift control rod.
  2. Remove the shift gate.

  

  1. Remove the shift control shaft roll pin.

  

  1. Remove the shift control shaft and shift fork selector lever.
  1. Remove the shift control rod.
  2. Remove the shift fork selector lever.
  1. Shift into second and fourth gears.

  

  1. WARNING: When removing the shift fork and shaft assembly the detent ball will fly out. Hold a shop towel over the detent ball and spring to prevent the ball from becoming airborne.

Remove the shift fork shaft assembly, detent ball and spring.

  

  1. Remove the output and input shafts as an assembly.

  

  1. Remove the differential.

  

  1. Remove the input bearing cups.

  

  1. Remove the input shaft oil seal.
  1. Attach Puller to the input shaft oil seal.
  2. Remove the input shaft oil seal.

  

  1. Remove the fifth shaft funnel.
  1. Remove the output shaft bearing cup.
  2. Remove the fifth shaft funnel.

  

  1. Remove the control selector plate and spacer.
  1. Remove the bolts.
  2. Remove the control selector plate and spacer.

  

  1. Remove the shift control shaft selector lever.
  1. Remove the bolt.
  2. Remove the shift control shaft selector lever.

  

  1. Remove and discard the roll pin.

  

  1. Remove the shift control shaft assembly.

  

  1. Use (A) collet, (B) actuator pin and (C) hammer from Blind Hole Puller Set to remove the (D) shifter shaft seal.

  

  1. Remove the vent tube.
  1. Remove the bolts.
  2. Remove the vent tube.

  

  1. Remove the retaining bolt and the vehicle speed sensor (VSS) .

  

  1. Use (A) Stator and Driven Sprocket Bearing Remover, (B) Disc Brake Piston Remover, and (C) Impact Slide Hammer to remove the (D) differential bearing cups.

  

  1. Remove and discard the reverse lever roll pin.

  

  1. Remove the reverse lever shaft.
  1. Remove the reverse lever shaft.
  2. Remove the reverse lever.

  

  1. Remove the park/neutral position (PNP) switch and gasket.

  

  1. Use (A) Bearing Cup Puller and (B) Impact Slide Hammer to remove the (C) differential seals.

  

  1. Use (A) Puller to remove the (B) input and output shaft bearing cups.