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DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSFORD1999WINDSTAR BASE, VAN CARGO, 3.8 4REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1856 (MANUAL TRANSAXLE)DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIESTRANSAXLE CASEDISASSEMBLY AND ASSEMBLY

1999 Ford Windstar Base, Van Cargo, 3.8 4

Disassembly and Assembly

1999 Ford Windstar Base, Van Cargo, 3.8 4SECTION Disassembly and Assembly

WARNING: This page is about a different car, the 2010 Mercury Milan and 2010 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

Place the transaxle clutch housing on a bench.
Remove the 2 vent cover bolts and the vent cover.

Fig 1: Locating Vent Cover Bolts
Courtesy of FORD MOTOR CO.
Using the Slide Hammer and Stator Case Bearing Remover, remove the differential bearing cup.
- Inspect the cup for wear or damage. Install a new cup as necessary.
- Always install new bearings and cups as a set.
Fig 2: Removing Differential Bearing Cup
Courtesy of FORD MOTOR CO.
Using a screwdriver, remove and discard the differential seal.

Fig 3: Removing Differential Seal
Courtesy of FORD MOTOR CO.
Remove the input shaft bearing cup.
- Inspect the cup for wear or damage. Install a new cup as necessary.
- Always install new bearings and cups as a set.
Fig 4: Locating Input Shaft Bearing Cup
Courtesy of FORD MOTOR CO.
Using a screwdriver, remove and discard the input shaft oil seal.

Fig 5: Removing Input Shaft Oil Seal
Courtesy of FORD MOTOR CO.
Remove the output shaft bearing cup and the funnel.
- Inspect the cup for wear or damage. Install a new cup as necessary.
- Always install new bearings and cups as a set.
Fig 6: Locating Output Shaft Bearing Cup
Courtesy of FORD MOTOR CO.
Remove the shift control selector plate bolts and the shift control selector plate.

Fig 7: Locating Shift Control Selector Plate With Bolts
Courtesy of FORD MOTOR CO.
Working on the transaxle case:
1. Remove the 2 shift lever assembly bolts and separate the boot from the case.
2. Separate the shift arm, boot and bushing from the shift lever assembly.
Fig 8: Identifying Shift Lever Assembly Bolts
Courtesy of FORD MOTOR CO.
Remove the control arm bolt.

Fig 9: Locating Control Arm Bolt
Courtesy of FORD MOTOR CO.
Pull the shift lever outward, then remove the washer, spring and the control arm.

Fig 10: Locating Washer, Spring & Control Arm
Courtesy of FORD MOTOR CO.
Remove the control arm key.

Fig 11: Locating Control Arm Key
Courtesy of FORD MOTOR CO.
Remove the shift lever from the case.
- Inspect all components for wear or damage. Install new components as necessary.
Inspect the shift lever bushing and replace if necessary.

Fig 12: Locating Shift Lever Bushing
Courtesy of FORD MOTOR CO.
Remove the shift lever boot.

Fig 13: Locating Shift Lever Boot
Courtesy of FORD MOTOR CO.
Remove the shift lever seal.

Fig 14: Locating Shift Lever Seal
Courtesy of FORD MOTOR CO.
Remove the input shaft bearing cup and shims.
- Inspect the cup for wear or damage. Install a new cup as necessary.
- Always install new bearings and cups as a set.
Remove the output shaft bearing cup and shims.
- Inspect the cup for wear or damage. Install a new cup as necessary.
- Always install new bearings and cups as a set.
Using the Slide Hammer and Stator Case Bearing Remover, remove the differential bearing cup and shims.
- Inspect the cup for wear or damage. Install a new cup as necessary.
- Always install new bearings and cups as a set.
Fig 15: Removing Differential Bearing Cup & Shims
Courtesy of FORD MOTOR CO.
Remove and discard the differential oil seal.

Fig 16: Removing Differential Oil Seal
Courtesy of FORD MOTOR CO.