2002 Ford Escape

2002 TRANSMISSION Manual Transaxle/Transmission - Escape

2002 TRANSMISSION

Manual Transaxle/Transmission - Escape

PECIFICATIONS
ENERAL SPECIFICATIONS

neral Specifications Chart

Item Specification
st gear and differential gear mm (in) 0.05-0.33 (0.002-0.013)
cond gear and secondary third gear mm (in) 0.18-0.51 (0.007-0.020)
cond gear and third gear mm (in) 0.05-0.25 (0.002-0.010)
urth gear and bearing cone mm (in) 0.17-0.42 (0.007-0.017)
earance
nchronizer blocking ring to gear mm (in) 0.8-1.5 (0.031-0.059)
st/second synchronizer to shift fork mm (in) 0.1-0.55 (0.004-0.021)
ird/forth synchronizer to shift fork mm (in) 0.1-0.55 (0.004-0.021)
th/reverse synchronizer to shift fork mm (in) 0.15-0.51 (0.005-0.020)
d play
put shaft mm (in) 0-0.05 (0-0.002)
tput shaft mm (in) 0-0.05 (0-0.002)
unout
put shaft gear mm (in) 0.05 (0.002)
tput shaft gear mm (in) 0.015 (0.0006)
cklash
de gears and pinions mm (in) 0.025-0.1 (0.001-0.004)
bricants and sealants
AE 75W90 Gear Oil F32Z-19C547-MA MAZDA 115A& API GL-4
emium Long Life Grease XG-1-C or -K ESA-M1C75-B
icone Gasket and Sealant F7AZ-19554-EA WSE-M4G323-A4

RQUE SPECIFICATIONS

RQUE SPECIFICATIONS
Description N.m Lb-Ft Lb-In
se cover bolts 10 - 89
utch slave cylinder 20 15 -
lts
utch slave cylinder line 20 15 -
acket bolts
fferential cover bolts 164 121 -
fferential cover screws 9 - 80

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10:05:52 a.m. Page 1 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

fferential turning 0.5 - 4.3

que
ain plug 47 35 -
ont to aft crossmember 90 66 -
lts
ont transaxle support 55 41 -
ulator bracket bolts
ont transaxle support 90 66 -
ulator bolt
ont wire harness 12 9 -
acket nut
put shaft lock nut 160 118 -
H transaxle support 90 66 -
ulator bracket to
nsaxle bolt and nuts
H transaxle support 90 66 -
ulator to bracket bolt
H transaxle support 55 41 -
ulator to body bolts
ck bolt 18 13 -
tput shaft locknut 160 118 -
rk/neutral position 25 18 -
NP) switch
ar transaxle support 90 66 -
ulator bolt
ar transaxle support 90 66 -
ulator to subframe bolt
d nuts
ar transaxle support 90 66 -
ulator bracket to
nsaxle bolts
ar wire harness bracket 9 - 80
transaxle bolts
versing lamp switch 25 18 -
verse idler shaft lock 22 16 -
lt
ift gate bolt 13 10 -
ifter linkage nut 20 15 -
ift rail guide bolt 12 9 -
ift control selector 10 - 89
te 1
ift control selector 28 21 -
te 2
ift control shaft 13 10 -

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

ector lever bolt

abilizer bar to transaxle 40 30 -
lt
arter motor bolts 45 33 -
ansaxle case to 45 33 -
wheel housing bolts
ansaxle flywheel 45 33 -
using to engine bolts
ansverse crossmember 115 85 -
lts
hicle speed sensor 7 - 62
SS) bolt

ESCRIPTION AND OPERATION

ANUAL TRANSAXLE

e G5M-R manual transaxle is a fully synchronized five-speed transaxle. The forward gears are selected by a
chronizer mechanism. Third gear (3GR), fourth gear (4GR) and the fifth speed cluster gear are mounted on
input shaft. First gear (1GR), second gear (2GR) and the reverse output gear are mounted on the output
ft. The helical-cut forward gears are in constant mesh with the corresponding gears on the opposing shaft.
e G5M-R features a synchronized reverse gear. The reverse gears have straight-cut teeth and are engaged
ough the reverse idler gear and bushing.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

. 1: Identifying Different Power Flows

urtesy of FORD MOTOR CO.

ernal Shift Linkage

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

e G5M-R manual transaxle is controlled by a floor-mounted gearshift lever located in the console panel. The
rshift lever is attached to the transaxle case through the gearshift lever stabilizer bar. Gearshift lever
vements are transferred through the gearshift linkage.

ernal Shift Linkage

e G5M-R manual transaxle is shifted internally by three shift forks. The fifth and reverse gear shifter fork
fts in and out of the fifth and reverse gears. The first/second and the third/fourth shift forks control all other
ward gear shifts.

verse Gear

e reverse idler gear and bushing is mounted on a reverse idler gear shaft supported at one end in the flywheel
using and at the other in the transaxle case. Because the reverse idler gear and bushing slides and rotates on
reverse idler gear shaft, the bushing is necessary to prevent metal-to-metal contact and wear.

en the reverse idler gear and bushing slides on the reverse idler gear shaft, it engages the reverse drive gear
the input shaft and the reverse gear on the output shaft. The driving gear is part of the input shaft and the
erse gear is machined on the outside diameter of the first/second synchronizer sleeve.

en the reverse idler gear and bushing rotates on the reverse idler gear shaft, it reverses the power flow to the
put shaft.

engage the reverse idler gear and bushing, the motion of the shift fork selector lever is transferred to the
erse gearshift lever through the shift gate. The reverse gearshift lever is mounted on a meshlock plunger that
ows it to act as a fulcrum. When the fifth/reverse gearshift selector arm moves its end of the shift fork
ector lever, the opposite end slides the reverse idler gear and bushing into engagement with the input shaft
output shaft reverse gears.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

. 2: Identifying Reverse Gear

urtesy of FORD MOTOR CO.

e G5M-R uses a reverse blocking ring mounted to the input shaft above the fifth speed gear. When the
nsaxle is engaged in reverse, the fifth gear synchronizer hub is pressed against the reverse blocking ring,
ich is pressed against the reverse blocking ring retainer. This retainer is connected to the input shaft. As the
cking ring cone surface engages the cone surface of the retainer, it stops rotation of the input shaft and
ows the smooth meshing of the reverse idler and the reverse speed gear.

ferential

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

. 3: Exploded View Of Differential

urtesy of FORD MOTOR CO.

e ends of the differential are supported on tapered roller differential bearings. The cups for these differential
rings are seated in the transaxle case and the flywheel housing. Differential bearing preload is set using a

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

ective differential bearing shim that is installed under the differential bearing cup in the transaxle case.

e differential includes the differential side gears and the shaft mounted differential pinion gears. Direct
tact between the gears and the differential case is prevented by the differential side gear thrust washers
alled under the gears. The differential pinion shaft is held in position by a differential pinion shaft lock pin
t extends through the end of the differential pinion shaft and the differential case.

. 4: Locating Speedometer Drive Gear

urtesy of FORD MOTOR CO.

e speedometer drive gear is also mounted on the differential case. It is located between the tapered roller
ferential bearing and the differential case. A tab on the speedometer drive gear and a matching slot in the
ferential case prevent the speedometer drive gear from spinning on the differential case.

AGNOSIS AND TESTING

ANUAL TRANSAXLE

fer to MANUAL TRANSAXLE/TRANSMISSION AND CLUTCH - GENERAL INFORMATION .

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

ENERAL PROCEDURES
ANSAXLE DRAINING AND FILLING

vehicles

1. Raise and support the vehicle.

2. Remove the drain plug and drain the fluid.

Fig. 5: Removing Drain Plug And Drain Fluid

Courtesy of FORD MOTOR CO.

3. NOTE: Use a new gasket on the drain plug. Install the drain plug.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 6: Installing Drain Plug

Courtesy of FORD MOTOR CO.

4. Remove the LH splash shield.

4X4 vehicles

5. Remove the plug.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 7: Removing Plug (4X4 Vehicles)

Courtesy of FORD MOTOR CO.

4X2 vehicles

6. Remove the plug.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 8: Removing Plug (4X2 Vehicles)

Courtesy of FORD MOTOR CO.

NOTE: 4X2 shown, 4X4 similar.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 9: Filling Transmission With Gear Oil

Courtesy of FORD MOTOR CO.

7. Fill the transmission with gear oil until level with the fill hole.

NOTE: 4X2 shown, 4X4 similar.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 10: Installing Fill Plug

Courtesy of FORD MOTOR CO.

8. Install the fill plug.

9. Install the LH splash shield.

CAUTION: If any of the following conditions exist, install a new bearing.

ARINGS

1. Inspect the bearing for a bent cage.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 11: Inspecting Bearing For A Bent Cage

Courtesy of FORD MOTOR CO.

2. Inspect the bearings for galling (metal smears on the roller ends).

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 12: Inspecting Bearings For Galling

Courtesy of FORD MOTOR CO.

3. Inspect the bearings for brinelling (surface indentation in the race).

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 13: Inspecting Bearings For Brinelling

Courtesy of FORD MOTOR CO.

4. Inspect the bearing for a cracked inner race.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 14: Inspecting Bearing For A Cracked Inner Race

Courtesy of FORD MOTOR CO.

CAUTION: If etching is present, inspect the seals.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 15: Inspecting Bearing And Race For Etching

Courtesy of FORD MOTOR CO.

5. Inspect the bearing and race for etching.

6. Inspect the bearing for heat discoloration (dark blue).

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 16: Inspecting Bearing For Heat Discoloration

Courtesy of FORD MOTOR CO.

7. Inspect the bearing for fatigue spalling (metal flaking).

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 17: Inspecting Bearing For Fatigue Spalling

Courtesy of FORD MOTOR CO.

-VEHICLE REPAIR
ALFSHAFT OIL SEAL

cial Tool(s)

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

. 18: Identifying Special Tool(s)

urtesy of FORD MOTOR CO.

moval

1. Remove the halfshaft. Refer to AXLE SHAFTS .

2. NOTE: RH side shown, LH side similar. Remove the halfshaft seal.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 19: Removing Halfshaft Seal

Courtesy of FORD MOTOR CO.

tallation

NOTE: RH side shown, LH side similar.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 20: Installing New Halfshaft Seal Using Special Tool

Courtesy of FORD MOTOR CO.

1. Using the special tool, install the new halfshaft seal.

2. Install the halfshaft. Refer to AXLE SHAFTS .

HICLE SPEED SENSOR (VSS)-4X2

moval and Installation

1. Disconnect the vehicle speed sensor (VSS) electrical connector.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 21: Disconnecting Vehicle Speed Sensor

Courtesy of FORD MOTOR CO.

2. Remove the bolt and the VSS.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 22: Removing VSS

Courtesy of FORD MOTOR CO.

3. To install, reverse the removal procedure.

HICLE SPEED SENSOR (VSS)-4X4

moval and Installation

1. Disconnect the vehicle speed sensor (VSS) electrical connector.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 23: Disconnecting Vehicle Speed Sensor (VSS) Electrical Connector

Courtesy of FORD MOTOR CO.

2. Raise the vehicle on the hoist.

3. Remove the bolt and the VSS.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 24: Removing VSS

Courtesy of FORD MOTOR CO.

4. To install, reverse the removal procedure.

ANSAXLE LH SUPPORT INSULATOR

cial Tool(s)

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

. 25: Identifying Special Tool(s)

urtesy of FORD MOTOR CO.

moval and Installation

1. Using the special tool, support the engine.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 26: Supporting Engine Using Special Tool

Courtesy of FORD MOTOR CO.

2. Remove the air cleaner.

3. Remove the LH transaxle support insulator.
1. Remove the bolt.
2. Remove the four bolts.
3. Remove the LH transaxle support insulator.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 27: Removing LH Transaxle Support Insulator

Courtesy of FORD MOTOR CO.

4. To install, reverse the removal procedure.

ANSAXLE FRONT SUPPORT INSULATOR

cial Tool(s)

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

. 28: Identifying Special Tool(s)

urtesy of FORD MOTOR CO.

moval and Installation

1. Using the special tool, support the engine.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 29: Supporting Engine Using Special Tool

Courtesy of FORD MOTOR CO.

2. Remove the front transaxle support insulator bolt.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 30: Removing Front Transaxle Support Insulator Bolt

Courtesy of FORD MOTOR CO.

3. Raise and support the vehicle.

4. Remove the transverse crossmember.
1. Remove the bolts.
2. Remove the transverse crossmember.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 31: Removing Transverse Crossmember

Courtesy of FORD MOTOR CO.

5. Remove the front-to-aft crossmember.

1. Remove the splash shield screw.
2. Remove the bolts and the nut.
3. Remove the front-to-aft crossmember.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 32: Removing Front-To-Aft Crossmember

Courtesy of FORD MOTOR CO.

6. To install, reverse the removal procedure.

ANSAXLE REAR SUPPORT INSULATOR

moval and Installation

1. Remove the rear transaxle support insulator.

1. Remove the bolt.
2. Remove the bolt and the nuts.
3. Remove the rear transaxle support insulator.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 33: Removing Rear Transaxle Support Insulator

Courtesy of FORD MOTOR CO.

2. To install, reverse the removal procedure.

EMOVAL
ANSAXLE

cial Tool(s)

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

. 34: Identifying Special Tool(s)

urtesy of FORD MOTOR CO.

moval

vehicles

1. Remove the battery tray.

2. Remove the engine air cleaner housing bolt.
1. Disconnect the mass air flow sensor electrical connector.
2. Remove the air cleaner housing bolt.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 35: Removing Air Cleaner Housing Bolt

Courtesy of FORD MOTOR CO.

3. Remove the engine air cleaner housing and the air cleaner outlet tube.
1. Disconnect the accelerator cable from the air cleaner outlet tube.
2. Disconnect the emission management tube and hose.
3. Disconnect the crankcase ventilation hose.
4. Loosen the air cleaner outlet tube clamp.
5. Remove the engine air cleaner housing and the air cleaner outlet tube.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 36: Removing Engine Air Cleaner Housing And Air Cleaner Outlet Tube
Courtesy of FORD MOTOR CO.

4. Disconnect the reversing lamp switch electrical connector.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 37: Disconnecting Reversing Lamp Switch Electrical Connector

Courtesy of FORD MOTOR CO.

5. Position the front wire harness bracket aside.

1. Remove the nut.
2. Position the front wire harness bracket aside.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 38: Positioning Front Wire Harness Bracket Aside

Courtesy of FORD MOTOR CO.

6. Remove the front wire harness bracket spacer.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 39: Removing Front Wire Harness Bracket Spacer

Courtesy of FORD MOTOR CO.

7. Disconnect the wire harness from the rear wire harness bracket.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 40: Disconnecting Wire Harness From Rear Wire Harness Bracket
Courtesy of FORD MOTOR CO.

8. Disconnect the park/neutral position (PNP) electrical connector.

1. Disconnect the electrical connector from the rear wire harness bracket.
2. Disconnect the PNP electrical connector.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 41: Disconnecting PNP Electrical Connector

Courtesy of FORD MOTOR CO.

9. Position the rear wire harness bracket aside.

1. Remove the bolts.
2. Position the rear wire harness bracket aside.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 42: Positioning Rear Wire Harness Bracket Aside

Courtesy of FORD MOTOR CO.

0. Disconnect the vehicle speed sensor (VSS) electrical connector.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 43: Disconnecting Vehicle Speed Sensor (VSS) Electrical Connector

Courtesy of FORD MOTOR CO.

1. Disconnect the clutch slave cylinder line from the bracket.

1. Remove the clip.
2. Disconnect the clutch slave cylinder line from the bracket.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 44: Disconnecting Clutch Slave Cylinder Line From Bracket

Courtesy of FORD MOTOR CO.

2. Position the clutch slave cylinder aside.

1. Remove the bolts.
2. Position the clutch slave cylinder aside.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 45: Positioning Clutch Slave Cylinder

Courtesy of FORD MOTOR CO.

3. Using the special tool, support the engine.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 46: Supporting Engine Using Special Tool

Courtesy of FORD MOTOR CO.

4. Remove the LH transaxle support insulator.

1. Remove the five bolts.
2. Remove the LH transaxle support insulator.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 47: Removing LH Transaxle Support Insulator

Courtesy of FORD MOTOR CO.

5. Remove the LH transaxle support insulator bracket.

1. Remove the nuts and the bolt.
2. Remove the LH transaxle support insulator bracket.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 48: Removing LH Transaxle Support Insulator Bracket

Courtesy of FORD MOTOR CO.

6. Remove the rear transaxle support insulator bolt.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 49: Removing Rear Transaxle Support Insulator Bolt

Courtesy of FORD MOTOR CO.

7. Remove the front transaxle support insulator and bracket.

1. Remove the five bolts.
2. Remove the front transaxle support insulator and bracket.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 50: Removing Front Transaxle Support Insulator And Bracket

Courtesy of FORD MOTOR CO.

8. Position the starter motor aside.

1. Remove the bolts.
2. Position the starter motor aside.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 51: Positioning Starter Motor

Courtesy of FORD MOTOR CO.

9. Remove the top transaxle flywheel housing bolts.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 52: Removing Top Transaxle Flywheel Housing Bolts

Courtesy of FORD MOTOR CO.

0. Remove the front transaxle flywheel housing bolts.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 53: Removing Front Transaxle Flywheel Housing Bolts

Courtesy of FORD MOTOR CO.

Vehicles with all wheel drive

1. Remove the transfer case. Refer to REMOVAL .

All vehicles

2. Remove the LH halfshaft. Refer to AXLE SHAFTS .

3. Drain the transaxle fluid.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 54: Locating Transaxle Fluid Drain Nut

Courtesy of FORD MOTOR CO.

4. Install the drain plug.

artes, 07 de Enero de 2014 10:05:58 a.m. Page 58 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 55: Installing Drain Plug

Courtesy of FORD MOTOR CO.

5. Remove the rear transaxle support insulator bracket.

1. Remove the bolts.
2. Remove the rear transaxle support insulator bracket.

artes, 07 de Enero de 2014 10:05:59 a.m. Page 59 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 56: Removing Rear Transaxle Support Insulator Bracket

Courtesy of FORD MOTOR CO.

6. Disconnect the shifter linkage and stabilizer bar.

1. Remove the bolt.
2. Position the stabilizer bar aside.
3. Remove the bolt and nut.
4. Position the shifter linkage aside.

artes, 07 de Enero de 2014 10:05:59 a.m. Page 60 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 57: Disconnecting Shifter Linkage And Stabilizer Bar

Courtesy of FORD MOTOR CO.

7. Remove the transverse crossmember.

1. Remove the bolts.
2. Remove the transverse crossmember.

artes, 07 de Enero de 2014 10:05:59 a.m. Page 61 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 58: Removing Transverse Crossmember

Courtesy of FORD MOTOR CO.

8. Remove the front-to-aft crossmember.

1. Remove the splash shield screw.
2. Remove the bolts and the nut.
3. Remove the front-to-aft crossmember.

artes, 07 de Enero de 2014 10:05:59 a.m. Page 62 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 59: Removing Front-To-Aft Crossmember

Courtesy of FORD MOTOR CO.

9. Remove the LH side splash shield screws and the pin-type retainer.

artes, 07 de Enero de 2014 10:06:00 a.m. Page 63 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 60: Removing LH Side Splash Shield Screws And Pin-Type Retainer
Courtesy of FORD MOTOR CO.

0. Remove the LH side splash shield.

1. Remove the screws.
2. Remove the LH side splash shield.

artes, 07 de Enero de 2014 10:06:00 a.m. Page 64 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 61: Removing LH Side Splash Shield

Courtesy of FORD MOTOR CO.

1. Support the transaxle.

artes, 07 de Enero de 2014 10:06:00 a.m. Page 65 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 62: Supporting Transaxle

Courtesy of FORD MOTOR CO.

NOTE: Front wheel drive shown, all wheel drive similar.

artes, 07 de Enero de 2014 10:06:00 a.m. Page 66 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 63: Removing Seven Transaxle Flywheel Housing Bolts

Courtesy of FORD MOTOR CO.

2. Remove the seven transaxle flywheel housing bolts.

3. Remove the transaxle.
 Separate the RH halfshaft from the transaxle before lowering transaxle.

artes, 07 de Enero de 2014 10:06:00 a.m. Page 67 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 64: Separating RH Halfshaft From Transaxle

Courtesy of FORD MOTOR CO.

SASSEMBLY
ANSAXLE

cial Tool(s)

artes, 07 de Enero de 2014 10:06:01 a.m. Page 68 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

. 65: Special Tool(s) (1 Of 2)

urtesy of FORD MOTOR CO.

artes, 07 de Enero de 2014 10:06:01 a.m. Page 69 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

artes, 07 de Enero de 2014 10:06:01 a.m. Page 70 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

. 66: Special Tool(s) (2 Of 2)

urtesy of FORD MOTOR CO.

. 67: Exploded View Of Transaxle

urtesy of FORD MOTOR CO.

artes, 07 de Enero de 2014 10:06:01 a.m. Page 71 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

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.

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. Failure to follow these instructions may result in
personal injury.

3. Clean out all holes and passages with compressed air and verify that there are no obstructions.
4. Using the special tool, mount the transaxle to a bench.

Fig. 68: Mounting Transaxle To A Bench Using Special Tool

Courtesy of FORD MOTOR CO.

5. Remove the clutch release fork and bearing.

1. Remove the boot.
2. Remove the clutch release fork and bearing.

artes, 07 de Enero de 2014 10:06:01 a.m. Page 72 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 69: Removing Clutch Release Fork And Bearing

Courtesy of FORD MOTOR CO.

6. Remove the anchor bolt.

artes, 07 de Enero de 2014 10:06:01 a.m. Page 73 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 70: Removing Anchor Bolt

Courtesy of FORD MOTOR CO.

7. Remove the park/neutral position (PNP) switch.

artes, 07 de Enero de 2014 10:06:01 a.m. Page 74 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 71: Removing Park/Neutral Position Switch

Courtesy of FORD MOTOR CO.

8. Remove the bolt and the vehicle speed sensor (VSS).

artes, 07 de Enero de 2014 10:06:01 a.m. Page 75 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 72: Removing Bolt And Vehicle Speed Sensor

Courtesy of FORD MOTOR CO.

9. Rotate the transaxle 180 degrees.

0. Remove the reversing lamp switch.

artes, 07 de Enero de 2014 10:06:01 a.m. Page 76 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 73: Removing Reversing Lamp Switch

Courtesy of FORD MOTOR CO.

1. Remove the clutch slave cylinder line bracket.

1. Remove the bolts.
2. Remove the clutch slave cylinder line bracket.

artes, 07 de Enero de 2014 10:06:01 a.m. Page 77 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 74: Removing Clutch Slave Cylinder Line Bracket

Courtesy of FORD MOTOR CO.

2. Shift the transaxle into first gear.

3. Remove the case cover.
1. Remove the bolts.
2. Remove the case cover.

artes, 07 de Enero de 2014 10:06:01 a.m. Page 78 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 75: Removing Case Cover

Courtesy of FORD MOTOR CO.

CAUTION: Do not reuse locknuts.

artes, 07 de Enero de 2014 10:06:01 a.m. Page 79 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 76: Removing Input And Output Shaft Locknuts

Courtesy of FORD MOTOR CO.

4. Remove the input and output shaft locknuts and discard.

1. Using the special tool, keep the input shaft from turning.
2. Remove the input and output shaft locknuts and discard.
5. Remove the reverse synchronizer blocking ring retainer assembly.
1. Remove the spacer.
2. Remove the reverse synchronizer blocking ring retainer assembly.

artes, 07 de Enero de 2014 10:06:01 a.m. Page 80 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 77: Removing Input And Output Shaft Locknuts

Courtesy of FORD MOTOR CO.

CAUTION: The synchronizer blocking rings are not interchangeable. Make sure
to keep them in the order that they were removed.

artes, 07 de Enero de 2014 10:06:01 a.m. Page 81 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 78: Removing Reverse Synchronizer Blocking Ring

Courtesy of FORD MOTOR CO.

6. Remove the reverse synchronizer blocking ring.

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

artes, 07 de Enero de 2014 10:06:01 a.m. Page 82 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 79: Removing Reverse/Fifth Shift Fork Roll Pin

Courtesy of FORD MOTOR CO.

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

artes, 07 de Enero de 2014 10:06:01 a.m. Page 83 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 80: Removing Reverse/Fifth Shift Fork And Synchronizer Hub Assembly
Courtesy of FORD MOTOR CO.

9. Remove the synchronizer blocking ring.

artes, 07 de Enero de 2014 10:06:01 a.m. Page 84 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 81: Removing Synchronizer Blocking Ring

Courtesy of FORD MOTOR CO.

0. Remove the fifth speed cluster gear.

artes, 07 de Enero de 2014 10:06:01 a.m. Page 85 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 82: Removing Fifth Speed Cluster Gear

Courtesy of FORD MOTOR CO.

1. Remove the fifth gear bushing.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 83: Removing Fifth Gear Bushing

Courtesy of FORD MOTOR CO.

2. Remove the fifth gear spacer and fifth speed gear.

1. Remove the fifth gear spacer.
2. Remove the fifth speed gear.

artes, 07 de Enero de 2014 10:06:02 a.m. Page 87 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 84: Removing Fifth Gear Spacer And Fifth Speed Gear
Courtesy of FORD MOTOR CO.

3. Remove the reverse idler shaft lock bolt and shift rail guide bolt.

artes, 07 de Enero de 2014 10:06:02 a.m. Page 88 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 85: Removing Reverse Idler Shaft Lock Bolt

Courtesy of FORD MOTOR CO.

4. Remove the bolt, spring, and ball.

artes, 07 de Enero de 2014 10:06:02 a.m. Page 89 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 86: Removing Bolt, Spring, And Ball

Courtesy of FORD MOTOR CO.

5. Separate the transaxle case.

1. Remove the 15 transaxle case bolts.
2. Separate the transaxle case.

artes, 07 de Enero de 2014 10:06:02 a.m. Page 90 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 87: Separating Transaxle Case

Courtesy of FORD MOTOR CO.

6. Remove the magnet.

artes, 07 de Enero de 2014 10:06:02 a.m. Page 91 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 88: Removing Magnet

Courtesy of FORD MOTOR CO.

7. Remove the reverse idler gear.

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

artes, 07 de Enero de 2014 10:06:02 a.m. Page 92 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 89: Removing Reverse Idler Gear

Courtesy of FORD MOTOR CO.

8. Remove the shift gate bolt.

artes, 07 de Enero de 2014 10:06:02 a.m. Page 93 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 90: Removing Shift Gate Bolt

Courtesy of FORD MOTOR CO.

9. Remove the shift control shaft and shift gate.

1. Remove the shift control shaft.
2. Remove the shift gate.

artes, 07 de Enero de 2014 10:06:02 a.m. Page 94 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 91: Removing Shift Control Shaft And Shift Gate

Courtesy of FORD MOTOR CO.

0. Remove the shift lever shaft roll pin.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 92: Removing Shift Lever Shaft Roll Pin

Courtesy of FORD MOTOR CO.

1. Remove the shift lever shaft and shift fork selector lever.
1. Remove the shift lever shaft.
2. Remove the shift fork selector lever.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 93: Removing Shift Lever Shaft And Shift Fork Selector Lever
Courtesy of FORD MOTOR CO.

2. Shift into second and fourth gears.

WARNING: When removing the gear shifter fork and main shift control 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.
Failure to follow these instructions may result in personal injury.

artes, 07 de Enero de 2014 10:06:02 a.m. Page 97 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 94: Removing Gear Shifter Fork And Main Shift Control Shaft Assembly
Courtesy of FORD MOTOR CO.

3. Remove the gear shifter fork and main shift control shaft assembly, detent ball and spring.
4. Remove the output and input shafts as an assembly.

artes, 07 de Enero de 2014 10:06:02 a.m. Page 98 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 95: Removing Output And Input Shafts

Courtesy of FORD MOTOR CO.

5. Remove the differential.

artes, 07 de Enero de 2014 10:06:03 a.m. Page 99 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 96: Removing Differential

Courtesy of FORD MOTOR CO.

NOTE: Flywheel housing side shown, transaxle case side similar.

artes, 07 de Enero de 2014 10:06:03 a.m. Page 100 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 97: Removing Input Shaft Bearing Cups

Courtesy of FORD MOTOR CO.

6. Remove the input shaft bearing cups.

7. Using the special tools, remove the input shaft seal.

artes, 07 de Enero de 2014 10:06:03 a.m. Page 101 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 98: Removing Input Shaft Seal Using Special Tools

Courtesy of FORD MOTOR CO.

NOTE: Flywheel housing side shown, transaxle case side similar.

artes, 07 de Enero de 2014 10:06:03 a.m. Page 102 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 99: Removing Output Shaft Bearing Cups

Courtesy of FORD MOTOR CO.

8. Remove the output shaft bearing cups.

9. Remove the funnel.

artes, 07 de Enero de 2014 10:06:03 a.m. Page 103 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 100: Removing Funnel

Courtesy of FORD MOTOR CO.

0. Remove the shift control selector plate and spacer.

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

artes, 07 de Enero de 2014 10:06:03 a.m. Page 104 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 101: Removing Shift Control Selector Plate And Spacer

Courtesy of FORD MOTOR CO.

1. Remove the shift control shaft selector lever.

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

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 102: Removing Shift Control Shaft Selector Lever

Courtesy of FORD MOTOR CO.

2. Remove and discard the roll pin.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 103: Removing Roll Pin

Courtesy of FORD MOTOR CO.

3. Remove the shift control shaft assembly.

artes, 07 de Enero de 2014 10:06:03 a.m. Page 107 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 104: Removing Shift Control Shaft Assembly

Courtesy of FORD MOTOR CO.

4. Using the special tool, remove the shift control shaft seal.

artes, 07 de Enero de 2014 10:06:03 a.m. Page 108 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 105: Removing Shift Control Shaft Seal Using Special Tool
Courtesy of FORD MOTOR CO.

5. Remove the vent tube.

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

artes, 07 de Enero de 2014 10:06:03 a.m. Page 109 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 106: Removing Vent Tube

Courtesy of FORD MOTOR CO.

NOTE: Flywheel housing side shown, transaxle case side similar.

artes, 07 de Enero de 2014 10:06:03 a.m. Page 110 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 107: Removing Differential Bearing Cups Using Special Tools

Courtesy of FORD MOTOR CO.

6. Using the special tools, remove the differential bearing cups.

7. Remove and discard the reverse lever roll pin.

artes, 07 de Enero de 2014 10:06:03 a.m. Page 111 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 108: Removing Reverse Lever Roll Pin

Courtesy of FORD MOTOR CO.

8. Remove the reverse lever shaft.

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

artes, 07 de Enero de 2014 10:06:03 a.m. Page 112 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 109: Removing Reverse Lever

Courtesy of FORD MOTOR CO.

NOTE: Transaxle case side shown, flywheel housing side similar.

artes, 07 de Enero de 2014 10:06:03 a.m. Page 113 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 110: Removing Halfshaft Seals Using Special Tool

Courtesy of FORD MOTOR CO.

9. Using the special tool, remove the halfshaft seals.

SASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

PUT SHAFT

cial Tool(s)

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

. 111: Special Tool(s) (1 Of 3)

urtesy of FORD MOTOR CO.

artes, 07 de Enero de 2014 10:06:03 a.m. Page 115 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

. 112: Special Tool(s) (2 Of 3)

urtesy of FORD MOTOR CO.

artes, 07 de Enero de 2014 10:06:03 a.m. Page 116 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

. 113: Special Tool(s) (3 Of 3)

urtesy of FORD MOTOR CO.

cial Tool(s)

artes, 07 de Enero de 2014 10:06:03 a.m. Page 117 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

. 114: Exploded View Of Input Shaft

urtesy of FORD MOTOR CO.

assembly

CAUTION: When pressing off components, hold the shaft so that it does not fall.

1. Measure the input shaft clearances.

1. Measure the clearance between the third and second gears.
2. Measure the clearance between fourth gear and the bearing cone.

artes, 07 de Enero de 2014 10:06:04 a.m. Page 118 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 115: Measuring Input Shaft Clearances

Courtesy of FORD MOTOR CO.

artes, 07 de Enero de 2014 10:06:04 a.m. Page 119 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

2. Using the special tools and a press, press off the bearing (fourth gear end).

Fig. 116: Pressing Off Bearing (Fourth Gear End)

Courtesy of FORD MOTOR CO.

CAUTION: The synchronizer blocking rings are not interchangeable. Make sure
to keep them in the order that they were removed.

artes, 07 de Enero de 2014 10:06:04 a.m. Page 120 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 117: Removing Fourth Gear And Synchronizer Blocking Ring

Courtesy of FORD MOTOR CO.

3. Remove fourth gear and the synchronizer blocking ring.

4. Remove the snap ring.

artes, 07 de Enero de 2014 10:06:04 a.m. Page 121 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 118: Removing Snap Ring

Courtesy of FORD MOTOR CO.

CAUTION: The synchronizer blocking rings are not interchangeable. Make sure
to keep them in the order that they were removed.

NOTE: Inspect all the synchronizer components for wear and damage; refer to
SYNCHRONIZERS.

artes, 07 de Enero de 2014 10:06:04 a.m. Page 122 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 119: Inspecting All Synchronizer Components

Courtesy of FORD MOTOR CO.

5. Using the special tools and a press, press off the synchronizer hub assembly, synchronizer blocking ring,
and third gear.
6. Using the special tools and a press, press off the bearing (third gear end).

artes, 07 de Enero de 2014 10:06:04 a.m. Page 123 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 120: Pressing Off Bearing (Third Gear End)

Courtesy of FORD MOTOR CO.

7. Measure input shaft gear runout.

 Inspect the input shaft for worn or damaged gears.

artes, 07 de Enero de 2014 10:06:04 a.m. Page 124 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 121: Measuring Input Shaft Gear Runout

Courtesy of FORD MOTOR CO.

NOTE: Set the synchronizer ring squarely in the gear, then measure around the
circumference.

artes, 07 de Enero de 2014 10:06:04 a.m. Page 125 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 122: Inspecting Synchronizer Blocking Rings

Courtesy of FORD MOTOR CO.

8. Inspect the synchronizer blocking rings.

 Measure the clearance from the side of the gear.

 Inspect for smooth engagement with the gear.

 Inspect for worn or damaged teeth or tapper surface.

9. Inspect the synchronizer hub.

 Inspect for worn or damaged splines, synchronizer insert groove or end surface.

 Inspect for smooth hub sleeve movement when it is installed.

0. Measure the clearance between the third/fourth synchronizer hub and its shift fork.

artes, 07 de Enero de 2014 10:06:04 a.m. Page 126 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 123: Measuring Clearance Between Third/Fourth Synchronizer Hub

Courtesy of FORD MOTOR CO.

embly

NOTE: Whenever a bearing has been removed, a new one must be installed.

artes, 07 de Enero de 2014 10:06:04 a.m. Page 127 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 124: Pressing Third Gear Bearing

Courtesy of FORD MOTOR CO.

1. Using the special tools and a press, press on the bearing (third gear side).
2. Install the third gear.

NOTE: When installing the synchronizer blocking ring, align the synchronizer
blocking ring groove and synchronizer hub inserts.

NOTE: Make sure to have the ridge facing the third gear when installing the
synchronizer hub assembly.

NOTE: Make sure that the four grooves in the synchronizer hub are facing the
third gear.

artes, 07 de Enero de 2014 10:06:04 a.m. Page 128 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 125: Pressing On Synchronizer Blocking Ring And Synchronizer Hub Assembly
Courtesy of FORD MOTOR CO.

3. Using the special tools and a press, press on the synchronizer blocking ring and synchronizer hub
assembly.
4. Install the snap ring.

artes, 07 de Enero de 2014 10:06:04 a.m. Page 129 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 126: Installing Snap Ring

Courtesy of FORD MOTOR CO.

NOTE: When installing the synchronizer blocking ring, align the synchronizer
blocking ring groove and synchronizer hub inserts.

artes, 07 de Enero de 2014 10:06:04 a.m. Page 130 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 127: Pressing Synchronizer Blocking Ring

Courtesy of FORD MOTOR CO.

5. Using the special tools and a press, press on the synchronizer blocking ring, fourth gear, and the bearing.

NOTE: If not within specifications, disassemble and reassemble the input shaft
assembly.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 128: Measuring Input Shaft Clearances

Courtesy of FORD MOTOR CO.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

6. Measure the input shaft clearances.

1. Measure the clearance between the third and second gears.
2. Measure the clearance between the fourth gear and the bearing cone.

UTPUT SHAFT

cial Tool(s)

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

. 129: Identifying Special Tool(s)

urtesy of FORD MOTOR CO.

assembly

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

. 130: Exploded View Of Output Shaft

urtesy of FORD MOTOR CO.

CAUTION: When pressing off components, hold the shaft so that it does not fall.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

1. Measure the output shaft clearances.

1. Measure the clearance between first gear and the differential drive gear.
2. Measure the clearance between second gear and secondary third gear.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 131: Measuring Output Shaft Clearances

Courtesy of FORD MOTOR CO.

2. Using the special tools and press, press off the bearing (fourth gear end).

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 132: Pressing Off Fourth Gear End Bearing

Courtesy of FORD MOTOR CO.

3. Using the special tools and a press, press off the fourth speed gear.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 133: Pressing Off Fourth Speed Gear

Courtesy of FORD MOTOR CO.

4. Remove the snap ring.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 134: Removing Snap Ring

Courtesy of FORD MOTOR CO.

5. Using the special tools and a press, press off the third speed gear and second gear.

Fig. 135: Pressing Off Third Speed Gear And Second Gear
Courtesy of FORD MOTOR CO.

CAUTION: The synchronizer blocking rings are not interchangeable. Be sure to

keep them in the order that they were removed.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 136: Removing Synchronizer Blocking Ring

Courtesy of FORD MOTOR CO.

6. Remove the synchronizer blocking ring.

7. Remove the snap ring.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 137: Removing Snap Ring

Courtesy of FORD MOTOR CO.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

CAUTION: The synchronizer blocking rings are not interchangeable. Make sure
to keep them in the order that they were removed.

NOTE: Inspect all the synchronizer components for wear and damage; refer to
SYNCHRONIZERS.

Fig. 138: Pressing Off Synchronizer Hub, Synchronizer Blocking Ring, And First Gear
Courtesy of FORD MOTOR CO.

8. Using the special tools and a press, press off the synchronizer hub, synchronizer blocking ring, and first
gear.
9. Using the special tools and a press, press off the bearing (first gear end).

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 139: Pressing Off Bearing (First Gear End)

Courtesy of FORD MOTOR CO.

0. Measure output shaft gear runout.

 Inspect the output shaft for worn or damaged gears.

 Inspect the output shaft for clogged oil passage.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 140: Measuring Output Shaft Gear Runout

Courtesy of FORD MOTOR CO.

NOTE: Set the synchronizer ring squarely in the gear, then measure around the
circumference.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 141: Inspecting Synchronizer Blocking Ring

Courtesy of FORD MOTOR CO.

1. Inspect the synchronizer blocking ring.

 Measure the clearance from the side of the gear.

 Inspect for smooth engagement with the gear.

 Inspect for worn or damaged teeth or tapered surface.

2. Inspect the synchronizer hub.

 Inspect for worn or damaged splines, synchronizer insert groove or end surface.

 Inspect for smooth hub sleeve movement when it is installed.

3. Measure the clearance between the first/second synchronizer hub and its shift fork.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 142: Measuring Clearance Between First/Second Synchronizer Hub Its Shift Fork
Courtesy of FORD MOTOR CO.

embly

NOTE: Whenever a bearing has been removed, a new one must be installed.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 143: Pressing On Bearing (First Gear Side)

Courtesy of FORD MOTOR CO.

1. Using the special tools and a press, press on the bearing (first gear side).

NOTE: When installing the synchronizer blocking ring, align the synchronizer
blocking ring groove and synchronizer hub inserts.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 144: Pressing First Gear, Synchronizer Blocking Ring, And Reverse Gear
Courtesy of FORD MOTOR CO.

2. Using the special tools and a press, press on the first gear, synchronizer blocking ring, and reverse gear.
3. Install the snap ring.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 145: Installing Snap Ring

Courtesy of FORD MOTOR CO.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

NOTE: When installing the synchronizer blocking ring, align the synchronizer
blocking ring groove and synchronizer hub inserts.

Fig. 146: Pressing On Synchronizer Blocking Ring, Second Gear, And Third Speed Gear
Courtesy of FORD MOTOR CO.

4. Using the special tools and a press, press on the synchronizer blocking ring, second gear, and third speed
gear.
5. Install the snap ring.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 147: Installing Snap Ring

Courtesy of FORD MOTOR CO.

6. Using the special tools and a press, press on the fourth speed gear.

Fig. 148: Pressing On Fourth Speed Gear

Courtesy of FORD MOTOR CO.

7. Using the special tools and a press, press on the bearing (fourth gear side).

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 149: Pressing On Bearing (Fourth Gear Side)

Courtesy of FORD MOTOR CO.

NOTE: If not within specifications, disassemble and reassemble the output shaft
assembly.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 150: Identifying Clearances

Courtesy of FORD MOTOR CO.

8. Measure the output shaft clearances.

1. Measure the clearance between first gear and the differential drive gear.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

2. Measure the clearance between second gear and third gear.

NCHRONIZERS

assembly

OTE: First and second gear synchronizer shown; other synchronizers are similar.

NOTE: Prior to disassembly, note the position of the index marks.

Fig. 151: Disassembling Synchronizer Assembly

Courtesy of FORD MOTOR CO.

1. Disassemble the synchronizer assembly.

1. Remove the synchronizer blocking springs.
2. Remove the synchronizer hub inserts.
3. Separate the synchronizer hub from the sleeve.
2. Inspect all synchronizer components for wear and damage.

embly

1. NOTE: Align the index marks during assembly. Assemble the synchronizer.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

1. Position the synchronizer hub and sleeve together.

2. Install the synchronizer hub inserts.
3. Install the synchronizer blocking springs.

Fig. 152: Exploded View Of Synchronizer

Courtesy of FORD MOTOR CO.

FFERENTIAL

cial Tool(s)

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

. 153: Identifying Special Tool(s)

urtesy of FORD MOTOR CO.

assembly

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

. 154: Exploded View Of Differential

urtesy of FORD MOTOR CO.

1. Inspect the differential.

 Inspect for damaged or worn gears.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Inspect for cracked or damaged gear case.

2. Remove the differential cover.
1. Remove the differential cover bolts.
2. Remove the differential cover screws.
3. Remove the differential cover.

Fig. 155: Removing Differential Cover

Courtesy of FORD MOTOR CO.

3. Remove the differential side gear thrust washer and differential side gear.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 156: Removing Differential Side Gear Thrust Washer And Differential Side Gear
Courtesy of FORD MOTOR CO.

4. Remove the differential pinion shaft lock pins.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 157: Removing Differential Pinion Shaft Lock Pins

Courtesy of FORD MOTOR CO.

5. Remove the differential pinion shaft cage.

1. Remove the differential pinion shafts.
2. Remove the differential pinion shaft cage.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 158: Removing Differential Pinion Shaft Cage

Courtesy of FORD MOTOR CO.

6. Remove the differential pinion gears and thrust washers.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 159: Removing Differential Pinion Gears And Thrust Washers

Courtesy of FORD MOTOR CO.

7. Remove the differential side gear and thrust washer.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 160: Removing Differential Side Gear And Thrust Washer

Courtesy of FORD MOTOR CO.

8. Using the special tools, remove the bearing

(speedometer drive gear side).

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 161: Removing Bearing Using Special Tools

Courtesy of FORD MOTOR CO.

9. Remove the speedometer drive gear.

0. Remove the differential bearing.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 162: Removing Differential Bearing

Courtesy of FORD MOTOR CO.

embly

OTE: Whenever a bearing has been removed, a new bearing must be installed.

1. Using the special tool and a press, install the speedometer drive gear and the differential bearing.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 163: Installing Speedometer Drive Gear And Differential Bearing

Courtesy of FORD MOTOR CO.

2. Using the special tool, install the differential bearing.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 164: Installing Differential Bearing Using Special Tool

Courtesy of FORD MOTOR CO.

3. Install the differential side gear and thrust washer.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 165: Installing Differential Side Gear And Thrust Washer

Courtesy of FORD MOTOR CO.

4. Install the differential pinion gears and thrust washers.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 166: Installing Differential Pinion Gears And Thrust Washers

Courtesy of FORD MOTOR CO.

5. Install the differential pinion shaft cage.

1. Position the differential pinion shaft cage.
2. Install the differential pinion shafts.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 167: Installing Differential Pinion Shaft Cage

Courtesy of FORD MOTOR CO.

6. Install the differential pinion shaft lock pins.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 168: Installing Differential Pinion Shaft Lock Pins

Courtesy of FORD MOTOR CO.

7. Install the differential side gear thrust washer and differential side gear.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 169: Installing Differential Side Gear Thrust Washer And Differential Side Gear
Courtesy of FORD MOTOR CO.

8. Install the differential cover.

1. Position the differential cover.
2. Install the differential cover screws.
3. Install the differential cover bolts.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 170: Installing Differential Cover

Courtesy of FORD MOTOR CO.

SSEMBLY
ANSAXLE

cial Tool(s)

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

. 171: Special Tool(s) (1 Of 2)

urtesy of FORD MOTOR CO.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

. 172: Special Tool(s) (2 Of 2)

urtesy of FORD MOTOR CO.

embly

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

CAUTION: 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. Using the special tool, install the input shaft seal.

Fig. 173: Installing Input Shaft Seal Using Special Tool

Courtesy of FORD MOTOR CO.

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

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 174: Installing Input Shaft Bearing Cup

Courtesy of FORD MOTOR CO.

3. Install the input shaft.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 175: Installing Input Shaft

Courtesy of FORD MOTOR CO.

4. Position the bearing cup onto the bearing.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 176: Positioning Bearing Cup Onto Bearing

Courtesy of FORD MOTOR CO.

5. Position the special tools.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 177: Positioning Special Tools

Courtesy of FORD MOTOR CO.

6. Install the transaxle case.

1. Position the transaxle case.
2. Install the bolts.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 178: Installing Transaxle Case

Courtesy of FORD MOTOR CO.

7. Mount a dial indicator to the transaxle case.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 179: Mounting A Dial Indicator To Transaxle Case

Courtesy of FORD MOTOR CO.

8. Rotate the input shaft to seat the bearings.

9. Zero the dial indicator.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 180: Positioning Dial Indicator On Zero

Courtesy of FORD MOTOR CO.

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

artes, 07 de Enero de 2014 10:06:07 a.m. Page 186 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 181: Rotating Input Shaft Until Dial Indicator Returns To Zero
Courtesy of FORD MOTOR CO.

0. Rotate the input shaft until the dial indicator returns to zero then raise the input shaft and read the end
play.
1. Repeat the previous step to obtain three readings within 0.10 mm (0.004 in) of each other. Use the
formula below to select the correct shim size.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 182: Input Shaft Shim Size Formula

Courtesy of FORD MOTOR CO.

CAUTION: Do not use more than two shims.

2. 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.
3. Remove the transaxle case, special tools, bearing cup, and input shaft.
4. Install the shim.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 183: Installing Shim

Courtesy of FORD MOTOR CO.

5. Using the special tools, install the input shaft bearing cup.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 184: Installing Input Shaft Bearing Cup

Courtesy of FORD MOTOR CO.

6. Install the funnel.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 185: Installing Funnel

Courtesy of FORD MOTOR CO.

7. Using the special tools, install the output shaft bearing cup.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 186: Installing Output Shaft Bearing Cup Using Special Tools
Courtesy of FORD MOTOR CO.

8. Install the output shaft.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 187: Installing Output Shaft

Courtesy of FORD MOTOR CO.

9. Position the bearing cup onto the bearing.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 188: Positioning Bearing Cup Onto Bearing

Courtesy of FORD MOTOR CO.

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

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 189: Positioning Special Tools

Courtesy of FORD MOTOR CO.

0. Position the special tools.

1. Install the transaxle case.
1. Position the transaxle case.
2. Install the bolts.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 190: Installing Transaxle Case

Courtesy of FORD MOTOR CO.

2. Install a dial indicator on the transaxle case.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 191: Installing A Dial Indicator On Transaxle Case

Courtesy of FORD MOTOR CO.

3. Rotate the output shaft to seat the bearings.

4. Zero the dial indicator.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 192: Positioning Dial Indicator On Zero

Courtesy of FORD MOTOR CO.

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

artes, 07 de Enero de 2014 10:06:08 a.m. Page 198 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 193: Rotating Output Shaft Until Dial Indicator Returns To Zero
Courtesy of FORD MOTOR CO.

5. Rotate the output shaft until the dial indicator returns to zero then raise the output shaft and read the end
play.
6. Repeat the previous step to obtain three readings within 0.10 mm (0.004 in) of each other. Use the
formula below to select the correct shim size.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 194: Output Shaft Shim Size Formula

Courtesy of FORD MOTOR CO.

CAUTION: Do not use more than two shims.

7. 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.
8. Remove the transaxle case, special tools, bearing cup and output shaft.
9. Install the shim.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 195: Removing Transaxle Case

Courtesy of FORD MOTOR CO.

0. Using the special tools, install the output shaft bearing cup.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 196: Installing Output Shaft Bearing Cup

Courtesy of FORD MOTOR CO.

1. Using the special tools, install the differential bearing cup into the flywheel housing.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 197: Installing Differential Bearing Cup Into Flywheel Housing

Courtesy of FORD MOTOR CO.

2. Install the differential.

artes, 07 de Enero de 2014 10:06:09 a.m. Page 203 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 198: Installing Differential

Courtesy of FORD MOTOR CO.

3. Position the bearing cup onto the bearing.

artes, 07 de Enero de 2014 10:06:09 a.m. Page 204 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 199: Positioning Bearing Cup Onto Bearing

Courtesy of FORD MOTOR CO.

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

artes, 07 de Enero de 2014 10:06:09 a.m. Page 205 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 200: Positioning Special Tools

Courtesy of FORD MOTOR CO.

4. Position the special tools.

5. Install the transaxle case.
1. Position the transaxle case.
2. Install the bolts.

artes, 07 de Enero de 2014 10:06:09 a.m. Page 206 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 201: Installing Transaxle Case

Courtesy of FORD MOTOR CO.

6. Using the special tool, adjust gauge until the free play is removed. Turn gauge back together.

artes, 07 de Enero de 2014 10:06:09 a.m. Page 207 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 202: Adjusting Gauge Until Free Play Is Removed

Courtesy of FORD MOTOR CO.

7. Insert the special tool through the transaxle case and engage the differential pinion shaft.

artes, 07 de Enero de 2014 10:06:09 a.m. Page 208 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 203: Inserting Special Tool Through Transaxle Case

Courtesy of FORD MOTOR CO.

8. Using the special tools, adjust gauge until the differential rotation is within specification.

artes, 07 de Enero de 2014 10:06:09 a.m. Page 209 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 204: Adjusting Gauge Until Differential Rotation Is Within Specification

Courtesy of FORD MOTOR CO.

9. Measure the gap in the special tool.

artes, 07 de Enero de 2014 10:06:09 a.m. Page 210 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 205: Measuring Gap In Special Tool

Courtesy of FORD MOTOR CO.

0. Add 0.15 mm (0.0059 in) to the measurement to achieve the final clearance.

CAUTION: Do not use more than two differential shims.

artes, 07 de Enero de 2014 10:06:09 a.m. Page 211 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

artes, 07 de Enero de 2014 10:06:09 a.m. Page 212 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 206: Differential Shims Specification Chart

Courtesy of FORD MOTOR CO.

1. Use the following chart to select the differential bearing shims that are closest to (or slightly larger than)
the value obtained in Step 40.
2. Remove the transaxle case, special tools, bearing cup, and differential.
3. Install the differential bearing cup shim(s) into the transaxle case.

Fig. 207: Installing Differential Bearing Cup Shim

Courtesy of FORD MOTOR CO.

4. Using the special tools, install the differential bearing cup into the transaxle case.

artes, 07 de Enero de 2014 10:06:09 a.m. Page 213 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 208: Installing Differential Bearing Cup Into Transaxle Case

Courtesy of FORD MOTOR CO.

NOTE: Transaxle case side shown, flywheel housing side similar.

artes, 07 de Enero de 2014 10:06:09 a.m. Page 214 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 209: Installing Halfshaft Seals Using Special Tool

Courtesy of FORD MOTOR CO.

5. Using the special tool, install the halfshaft seals.

6. Install the reverse lever and shaft.
1. Position the reverse lever.
2. Install the reverse lever shaft.

artes, 07 de Enero de 2014 10:06:10 a.m. Page 215 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 210: Installing Reverse Lever Shaft

Courtesy of FORD MOTOR CO.

7. Install the reverse lever roll pin.

artes, 07 de Enero de 2014 10:06:10 a.m. Page 216 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 211: Installing Reverse Lever Roll Pin

Courtesy of FORD MOTOR CO.

8. Install the vent tube and the vent tube bolts.

artes, 07 de Enero de 2014 10:06:10 a.m. Page 217 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 212: Installing Vent Tube And Vent Tube Bolts

Courtesy of FORD MOTOR CO.

9. Using the special tool, install the shift control shaft seal.

artes, 07 de Enero de 2014 10:06:10 a.m. Page 218 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 213: Installing Shift Control Shaft Seal

Courtesy of FORD MOTOR CO.

NOTE: Install the boot with the drain hole facing downward when installed in the
vehicle.

artes, 07 de Enero de 2014 10:06:10 a.m. Page 219 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 214: Installing Shift Control Shaft Assembly

Courtesy of FORD MOTOR CO.

0. Install the shift control shaft assembly.

1. Install a new roll pin.

artes, 07 de Enero de 2014 10:06:10 a.m. Page 220 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 215: Installing A New Roll Pin

Courtesy of FORD MOTOR CO.

2. Install the shift control shaft selector lever.

1. Position the shift control shaft selector lever.
2. Install the shift control shaft selector lever bolt.

artes, 07 de Enero de 2014 10:06:10 a.m. Page 221 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 216: Installing Shift Control Shaft Selector Lever

Courtesy of FORD MOTOR CO.

3. Install the shift control selector plate and spacer.

1. Position the shift control selector plate and spacer.
2. Install the bolts.

artes, 07 de Enero de 2014 10:06:10 a.m. Page 222 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 217: Installing Shift Control Selector Plate And Spacer

Courtesy of FORD MOTOR CO.

4. Install the differential.

artes, 07 de Enero de 2014 10:06:10 a.m. Page 223 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 218: Installing Differential

Courtesy of FORD MOTOR CO.

5. Install the output and input shafts as an assembly.

artes, 07 de Enero de 2014 10:06:10 a.m. Page 224 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 219: Installing Output And Input Shafts

Courtesy of FORD MOTOR CO.

6. Install the gear shifter fork and main shift control shaft assembly, spring and detent ball.

artes, 07 de Enero de 2014 10:06:10 a.m. Page 225 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 220: Installing Gear Shifter Fork And Main Shift Control Shaft Assembly
Courtesy of FORD MOTOR CO.

7. Shift into second and fourth gears.

8. Install the shift lever shaft and shift fork selector lever.
1. Install the shift fork selector lever.
2. Install the shift lever shaft.

artes, 07 de Enero de 2014 10:06:10 a.m. Page 226 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 221: Installing Shift Lever Shaft And Shift Fork Selector Lever
Courtesy of FORD MOTOR CO.

9. Install the shift lever shaft roll pin.

artes, 07 de Enero de 2014 10:06:10 a.m. Page 227 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 222: Installing Shift Lever Shaft Roll Pin

Courtesy of FORD MOTOR CO.

0. Install the shift control shaft and shift gate.

1. Install the shift gate.
2. Install the shift control shaft.

artes, 07 de Enero de 2014 10:06:10 a.m. Page 228 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 223: Installing Shift Control Shaft And Shift Gate

Courtesy of FORD MOTOR CO.

1. Install the shift gate bolt.

artes, 07 de Enero de 2014 10:06:10 a.m. Page 229 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 224: Installing Shift Gate Bolt

Courtesy of FORD MOTOR CO.

2. Install the reverse idler gear.

1. Install reverse idler gear.
2. Install reverse idler gear shaft.

artes, 07 de Enero de 2014 10:06:11 a.m. Page 230 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 225: Installing Reverse Idler Gear

Courtesy of FORD MOTOR CO.

3. Install the magnet.

artes, 07 de Enero de 2014 10:06:11 a.m. Page 231 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 226: Installing Magnet

Courtesy of FORD MOTOR CO.

4. Position the gear selector arm and reverse idler gear shaft.
1. Align the end of the gear selector interlock sleeve with the gear selector arm.
2. Face the reverse idler gear shaft hole in the direction shown.

artes, 07 de Enero de 2014 10:06:11 a.m. Page 232 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 227: Positioning Gear Selector Arm And Reverse Idler Gear Shaft
Courtesy of FORD MOTOR CO.

CAUTION: The transaxle case must be installed within four minutes after
applying silicone gasket and sealant.

5. Apply a small bead of silicone gasket and sealant to the transaxle mating surface.
6. Install the transaxle case.
1. Position the transaxle case.
2. Install the 15 bolts.

artes, 07 de Enero de 2014 10:06:11 a.m. Page 233 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 228: Installing Transaxle Case

Courtesy of FORD MOTOR CO.

7. Install the lock bolt, spring, and ball.

artes, 07 de Enero de 2014 10:06:11 a.m. Page 234 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 229: Installing Lock Bolt, Spring, And Ball

Courtesy of FORD MOTOR CO.

CAUTION: Make sure that the shift rail guide bolt is in the groove of the shift rail.

artes, 07 de Enero de 2014 10:06:11 a.m. Page 235 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 230: Installing Reverse Idler Shaft Lock Bolt And Shift Rail Guide Bolt
Courtesy of FORD MOTOR CO.

8. Install the reverse idler shaft lock bolt and shift rail guide bolt.
9. Install the fifth speed gear and fifth gear spacer.
1. Install fifth speed gear.
2. Install the fifth gear spacer.

artes, 07 de Enero de 2014 10:06:11 a.m. Page 236 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 231: Installing Fifth Speed Gear And Fifth Gear Spacer
Courtesy of FORD MOTOR CO.

0. Install the fifth gear bushing.

artes, 07 de Enero de 2014 10:06:11 a.m. Page 237 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 232: Installing Fifth Gear Bushing

Courtesy of FORD MOTOR CO.

1. Measure the clearance between the fifth/reverse synchronizer sleeve and its shift fork.

artes, 07 de Enero de 2014 10:06:11 a.m. Page 238 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 233: Measuring Clearance Between Fifth/Reverse Synchronizer Sleeve And Its Shift Fork
Courtesy of FORD MOTOR CO.

2. Install the fifth speed cluster gear.

artes, 07 de Enero de 2014 10:06:11 a.m. Page 239 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 234: Installing Fifth Speed Cluster Gear

Courtesy of FORD MOTOR CO.

CAUTION: The synchronizer blocking rings are not interchangeable. Make sure
to keep them in the order that they were removed.

artes, 07 de Enero de 2014 10:06:11 a.m. Page 240 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 235: Installing Synchronizer Blocking Ring

Courtesy of FORD MOTOR CO.

3. Install the synchronizer blocking ring.

4. Install the fifth/reverse shift fork and synchronizer hub assembly.

artes, 07 de Enero de 2014 10:06:11 a.m. Page 241 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 236: Installing Fifth/Reverse Shift Fork And Synchronizer Hub Assembly
Courtesy of FORD MOTOR CO.

5. Install a new reverse/fifth shift fork roll pin.

artes, 07 de Enero de 2014 10:06:11 a.m. Page 242 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 237: Installing A New Reverse/Fifth Shift Fork Roll Pin

Courtesy of FORD MOTOR CO.

CAUTION: The synchronizer blocking rings are not interchangeable. Make sure
to install them in the order that they were removed.

artes, 07 de Enero de 2014 10:06:12 a.m. Page 243 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 238: Installing Reverse Synchronizer Blocking Ring

Courtesy of FORD MOTOR CO.

6. Install the reverse synchronizer blocking ring.

7. Install the reverse synchronizer blocking ring retainer assembly.
1. Install the reverse synchronizer blocking ring retainer assembly.
2. Install the spacer.

artes, 07 de Enero de 2014 10:06:12 a.m. Page 244 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 239: Installing Reverse Synchronizer Blocking Ring Retainer Assembly

Courtesy of FORD MOTOR CO.

8. Shift the transaxle into first gear.

CAUTION: Do not reuse locknuts.

CAUTION: Stake the locknuts.

artes, 07 de Enero de 2014 10:06:12 a.m. Page 245 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 240: Installing New Input And Output Shaft Locknuts

Courtesy of FORD MOTOR CO.

9. Install the input and output shaft locknuts.

1. Using the special tool, keep the input shaft from turning.
2. Install new input and output shaft locknuts.

CAUTION: The case cover must be installed within four minutes after applying
silicone gasket and sealant.

0. Apply a small bead of silicone gasket and sealant to the case and cover mating surface.
1. Install the case cover.
1. Position the case cover.
2. Install the bolts.

artes, 07 de Enero de 2014 10:06:12 a.m. Page 246 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 241: Installing Case Cover

Courtesy of FORD MOTOR CO.

2. Install the clutch slave cylinder line bracket.

1. Position the clutch slave cylinder line bracket.
2. Install the bolts.

artes, 07 de Enero de 2014 10:06:12 a.m. Page 247 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 242: Installing Clutch Slave Cylinder Line Bracket

Courtesy of FORD MOTOR CO.

3. Install the reversing lamp switch.

artes, 07 de Enero de 2014 10:06:12 a.m. Page 248 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 243: Installing Reversing Lamp Switch

Courtesy of FORD MOTOR CO.

4. Rotate the transaxle 180 degrees.

5. Install the park/neutral position (PNP) switch.

artes, 07 de Enero de 2014 10:06:12 a.m. Page 249 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 244: Installing Park/Neutral Position Switch

Courtesy of FORD MOTOR CO.

6. Install the anchor bolt.

artes, 07 de Enero de 2014 10:06:12 a.m. Page 250 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 245: Installing Anchor Bolt

Courtesy of FORD MOTOR CO.

7. Install the clutch release fork and bearing.

1. Install the clutch release fork and bearing.
2. Install the boot.

artes, 07 de Enero de 2014 10:06:12 a.m. Page 251 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 246: Installing Clutch Release Fork And Bearing

Courtesy of FORD MOTOR CO.

8. Remove the transaxle from the special tool.

artes, 07 de Enero de 2014 10:06:13 a.m. Page 252 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 247: Removing Transaxle From Special Tool

Courtesy of FORD MOTOR CO.

STALLATION
ANSAXLE

cial Tool(s)

artes, 07 de Enero de 2014 10:06:13 a.m. Page 253 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

. 248: Identifying Special Tool(s)

urtesy of FORD MOTOR CO.

tallation

1. Apply a thin coating of Premium Long Life Grease XG-1-C or K or equivalent meeting Ford
specification ESA-M1C75-B to the spline of the input shaft.

NOTE: On front wheel drive only vehicles, make sure to align the RH halfshaft
with the transaxle.

artes, 07 de Enero de 2014 10:06:13 a.m. Page 254 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 249: Securing Transaxle On A Transmission Jack

Courtesy of FORD MOTOR CO.

2. Secure the transaxle on a transmission jack. Raise the transaxle to the correct height and position the
transaxle to the engine.
3. Install the seven transaxle flywheel housing bolts.

artes, 07 de Enero de 2014 10:06:13 a.m. Page 255 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 250: Installing Seven Transaxle Flywheel Housing Bolts

Courtesy of FORD MOTOR CO.

4. Remove the transaxle support.

artes, 07 de Enero de 2014 10:06:13 a.m. Page 256 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 251: Removing Transaxle Support

Courtesy of FORD MOTOR CO.

5. Install the LH side splash shield.

1. Position the LH side splash shield.
2. Install the screws.

artes, 07 de Enero de 2014 10:06:13 a.m. Page 257 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 252: Installing LH Side Splash Shield

Courtesy of FORD MOTOR CO.

6. Install the LH side splash shield screws and the pin-type retainer.

artes, 07 de Enero de 2014 10:06:13 a.m. Page 258 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 253: Installing LH Side Splash Shield Screws And Pin-Type Retainer
Courtesy of FORD MOTOR CO.

7. Install the front-to-aft crossmember.

1. Position the front-to-aft crossmember.
2. Install the bolts and the nut.
3. Install the splash shield screw.

artes, 07 de Enero de 2014 10:06:13 a.m. Page 259 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 254: Installing Front-To-Aft Crossmember

Courtesy of FORD MOTOR CO.

8. Install the transverse crossmember.

1. Position the transverse crossmember.
2. Install the bolts.

artes, 07 de Enero de 2014 10:06:13 a.m. Page 260 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 255: Installing Transverse Crossmember

Courtesy of FORD MOTOR CO.

9. Connect the shifter linkage and stabilizer bar.

1. Position the shifter linkage.
2. Install the bolt and nut.
3. Position the stabilizer bar.
4. Install the bolt.

artes, 07 de Enero de 2014 10:06:13 a.m. Page 261 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 256: Connecting Shifter Linkage And Stabilizer Bar

Courtesy of FORD MOTOR CO.

0. Install the rear transaxle support insulator bracket.

1. Position the rear transaxle support insulator bracket.
2. Install the bolts.

artes, 07 de Enero de 2014 10:06:14 a.m. Page 262 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 257: Installing Rear Transaxle Support Insulator Bracket

Courtesy of FORD MOTOR CO.

1. Install the LH halfshaft. Refer to AXLE SHAFTS .

All Wheel Drive

2. Install the transfer case. Refer to INSTALLATION .

All

3. Install the front transaxle flywheel housing bolts.

artes, 07 de Enero de 2014 10:06:14 a.m. Page 263 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 258: Installing Front Transaxle Flywheel Housing Bolts

Courtesy of FORD MOTOR CO.

4. Install the top transaxle flywheel housing bolts.

artes, 07 de Enero de 2014 10:06:14 a.m. Page 264 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 259: Installing Top Transaxle Flywheel Housing Bolts

Courtesy of FORD MOTOR CO.

5. Install the starter motor.

1. Position the starter motor.
2. Position the electrical connector.
3. Install the bolts.

artes, 07 de Enero de 2014 10:06:14 a.m. Page 265 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 260: Installing Starter Motor

Courtesy of FORD MOTOR CO.

6. Install the front transaxle support insulator and bracket.

1. Position the front transaxle support insulator.
2. Install the four transaxle support insulator bracket bolts.
3. Install the front transaxle support insulator bolt.

artes, 07 de Enero de 2014 10:06:14 a.m. Page 266 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 261: Installing Front Transaxle Support Insulator Bolt

Courtesy of FORD MOTOR CO.

7. Install the rear transaxle support insulator bolt.

artes, 07 de Enero de 2014 10:06:14 a.m. Page 267 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 262: Installing Rear Transaxle Support Insulator Bolt

Courtesy of FORD MOTOR CO.

8. Install the LH transaxle support insulator bracket.

1. Position the LH transaxle support bracket.
2. Install the nuts and the bolt.

artes, 07 de Enero de 2014 10:06:14 a.m. Page 268 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 263: Installing LH Transaxle Support Insulator Bracket

Courtesy of FORD MOTOR CO.

9. Install the LH transaxle support insulator.

1. Position the LH transaxle support insulator.
2. Install the bolts.
3. Install the LH transaxle support insulator to bracket bolt.

artes, 07 de Enero de 2014 10:06:14 a.m. Page 269 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 264: Installing LH Transaxle Support Insulator

Courtesy of FORD MOTOR CO.

0. Remove the special tool.

artes, 07 de Enero de 2014 10:06:14 a.m. Page 270 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 265: Removing Special Tool

Courtesy of FORD MOTOR CO.

1. Install the clutch slave cylinder.

1. Position the clutch slave cylinder.
2. Install the bolts.

artes, 07 de Enero de 2014 10:06:14 a.m. Page 271 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 266: Installing Clutch Slave Cylinder

Courtesy of FORD MOTOR CO.

2. Attach the clutch slave cylinder line to the bracket.

1. Attach the clutch slave cylinder line to the bracket.
2. Install the clip.

artes, 07 de Enero de 2014 10:06:15 a.m. Page 272 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 267: Attaching Clutch Slave Cylinder Line To Bracket

Courtesy of FORD MOTOR CO.

3. Connect the vehicle speed sensor (VSS) electrical connector.

artes, 07 de Enero de 2014 10:06:15 a.m. Page 273 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 268: Connecting Vehicle Speed Sensor (VSS) Electrical Connector

Courtesy of FORD MOTOR CO.

4. Install the rear wire harness bracket.

1. Position the rear wire harness bracket.
2. Install the bolts.

artes, 07 de Enero de 2014 10:06:15 a.m. Page 274 © 2011 Mitchell Repair Information Company, LLC.
 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 269: Installing Rear Wire Harness Bracket

Courtesy of FORD MOTOR CO.

5. Connect the park/neutral position (PNP) switch electrical connector.

1. Connect the PNP switch electrical connector.
2. Attach the switch electrical connector to the rear wire harness bracket.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 270: Connecting Park/Neutral Position Switch Electrical Connector

Courtesy of FORD MOTOR CO.

6. Attach the wire harness to the rear wire harness bracket.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 271: Attaching Wire Harness To Rear Wire Harness Bracket

Courtesy of FORD MOTOR CO.

7. Install the front wire harness bracket spacer.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 272: Installing Front Wire Harness Bracket Spacer

Courtesy of FORD MOTOR CO.

8. Install the front wire harness bracket.

1. Position the front wire harness bracket.
2. Install the nut.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 273: Installing Front Wire Harness Bracket

Courtesy of FORD MOTOR CO.

9. Connect the reversing lamp switch electrical connector.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 274: Connecting Reversing Lamp Switch Electrical Connector

Courtesy of FORD MOTOR CO.

0. Install the engine air cleaner housing.

1. Position the air cleaner housing.
2. Install the air cleaner housing bolt.
3. Connect the mass air flow sensor electrical connector.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 275: Installing Engine Air Cleaner Housing

Courtesy of FORD MOTOR CO.

1. Install the air cleaner outlet tube.

1. Position the air cleaner outlet tube.
2. Tighten the air cleaner outlet tube clamp.
3. Connect the crankcase ventilation hose.
4. Attach the emission management tube and hose.
5. Attach the accelerator cable to the air cleaner outlet tube.

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 2002 Ford Escape
2002 TRANSMISSION Manual Transaxle/Transmission - Escape

Fig. 276: Installing Air Cleaner Outlet Tube

Courtesy of FORD MOTOR CO.

2. Install the battery tray.

3. Fill the transaxle. Refer to TRANSAXLE DRAINING AND FILLING.

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