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1. 2. 3. 4. 5. Install the spring retainers to the synchronizer hub. Align the scribe marks previously made on the synchronizer hub and the synchronizer sleeve. Install the synchronizer hub to the synchronizer sleeve with the three struts. Install the main drive synchronizer stop ring to the synchronizer sleeve. Install the drive sprocket to the mainshaft. 6. Install the synchronizer assembly to the mainshaft. 7. Install the synchronizer snap ring to the mainshaft. 8. Use a soft faced hammer in order to install the following components into the annulus gear: • The input gear • The planetary assembly 9. Install the snap ring to the input bearing. 10. Apply RTV GM P/N 12345739 or equivalent to the input shaft bearing retainer mating surfaces. 11. Apply threadlocker GM P/N 12345382 or equivalent to the input shaft bearing retainer bolts. 12. Install the input shaft bearing retainer and the input bearing retainer bolts to the front case half. Tighten Tighten the input bearing retainer bolts to 19 N·m (14 lb ft). Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 13. Install the three bolts that secure the encoder motor to the front case. Tighten Tighten the input bearing retainer bolts to 18 N·m (13 lb ft). 14. Install the range shift hub into the front case half. 15. Install the front output shaft to the front case half. 16. Install the driven sprocket to the chain. Important: The following components are installed into the front case half as an assembly: • The mainshaft assembly • The driven sprocket • The drive chain 17. 18. 19. 20. Install the drive chain onto the drive sprocket located on the mainshaft. Install the driven gear snap ring to the front output shaft. Install the mode shift fork onto the shift rail. Install the mode shift fork assembly through the range shift fork, onto the synchronizer sleeve, and into the front case half. 21. Install the mode fork shift spring to the shift rail. 22. Install the following components into the rear case half: • The oil pump pickup tube. • The oil tube connector • The pump pickup screen

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1994-1997 Ford Probe, Mazda MX3 with 4 cyl. & A/T 1994-2000 Mazda 626 with 4 cyl. & A/T 1998-2000 Mazda 626 with 6 cyl. & A/T 1995-2000 Ford Contour/Mercury Mystique with 6 cyl. & A/T 1999-2001 Mercury Cougar with A/T SUBJECT Vehicles with the Ford CD4E automatic transmission. CONDITION The driver’s side front CV axle has a 6-½ inch male inboard stub that fits into the transmission’s side gear. On the stub next to the housing seal surface is a carrier support surface that fits into the final drive sun gear inside the transmission (see figure 1). This sprocket assembly is chain driven with the reverse/overdrive sprocket by the planetary gear sets (see figure 2). The final drive sprocket assembly rides on the axle stub carrier support surface using a pressed, center bored bushing. This bushing wears the carrier support surface causing damage to the axle and eventually the transmission. SOLUTION If the carrier support surface of the axle being replaced appears rough and worn, then several possible failures need to be checked before replacing the axle or premature failure of the axle or possible damage to the transmission could occur. If the transmission’s internal oiling solenoid that lubricates this bushing fails, then the 2nd and 3rd gearshifts will not function. Although the Aftermarket lists this bushing, no tool exists to replace it. Ford only offer the bushing in a complete sprocket assembly making its replacement a very costly repair. The most common contributor to premature wear of this bushing is the vehicle not being within proper alignment specs. Without a four-wheel alignment, even though the front wheels may be centered to the rack, the rear thrust is pushing the front wheels causing stress on the front CV joints. The thrust forces acting on the front wheels while driving changes ALL the alignment specs resulting in the front wheels being in a constant turning action. This will wear the side gears and transmission seals as well as stressing this bushing. Another possible sign that alignment is affecting these items is a worn or torn inboard boot. Do not forget that worn motor mounts will also affect alignment thrust forces.

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4. Align crankshaft sprocket timing mark to the mark on oil pump housing (Fig. 122). NOTE: Lubricate timing chain and guides with engine oil before installation. 5. Place left side primary chain sprocket onto the chain so that the timing mark is located in-between the two (plated) timing links (Fig. 122). 6. Lower the primary chain with left side sprocket through the left cylinder head opening. NOTE: The camshaft sprockets can be allowed to float on the camshaft hub during installation 1 – CAMSHAFT TIMING MARKS 2 ? CHAIN GUIDE 3 – CRANKSHAFT TIMING MARKS 4 – CRANKSHAFT SPROCKET 5 – CHAIN TENSKJNER ARM 6 – CHAIN TENSIONER 7 – CAMSHAFT TIMING MARK 8 – INTAKE CAMSHAFT SPROCKETS 9 – CHAIN GUIDES 10 – WATER PUMP SPROCKET 7. Loosely position left side camshaft sprocket over camshaft hub. 8. Align timing (plated) link tq the crankshaft sprocket timing mark (Fig. 122). 9. Position primary chain onto water pump drive sprocket. 10. Align right camshaft sprocket timing mark to the timing (plated) link on the timing chain (Fig. 122) and loosely position over camshaft hub. 11. Verify that all chain timing (plated) links are properly aligned to the timing marks on all sprockets (Fig. 122). 12. Install left side lower chain guide and tensioner arm (Fig. 120). Tighten attaching bolts to 28 Nm (250 in. lbs.). NOTE: Inspect oil ring on chain guide access plug before installing. Replace O-ring as necessary. 13. Install chain guide access plug to left side cylinder head (Fig. 120). Tighten plug to 20 Nm (15 ft lbs.)

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An access plug is provided in the cam drive belt cover so that camshaft timing can be checked without removal of the cover or any other parts. 1. Remove access plug from cam drive belt cover. 2. Set crankshaft to TDC by aligning the TC mark on the timing belt cover with notch on crankshaft pulley. CAUTION: Always rotate crankshaft clockwise, which is the normal direction of rotation. Reverse rotation (counterclockwise) may cause the timing belt to jump time due to the arrangement of the timing belt tensioner. 3. Look through the access hole in the belt cover to be sure that the timing mark on the camshaft drive sprocket is aligned with the pointer on the inner timing belt cover assembly. 4. Remove the distributor cap and check that the distributor rotor is facing the No. 1 position on the distributor cap.

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New Process 241 (Manual Shift Transfer Case) Transfer Case Replacement Fig. 19 Transfer Case Exploded View. New Process Models 231, 233 & 241 Transfer Cases Fig. 20 Oil Pump, Pickup Tube & Screen. New Process Models 231, 233 & 241 Transfer Cases Fig. 21 Mode Fork & Shaft Assembly. New Process Models 231, 233 & 241 Transfer Cases Fig. 22 Shift Rail Assembly. Fig. 23 Input Gear Bearing Removal. Fig. 24 Front Output Shaft Rear Bearing Removal. Fig. 19 Transfer Case Exploded View. Fig. 25 Installing Needle Bearing To Front Drive Sprocket. Fig. 26 Installing Pump Retainer Housing Bearing. Fig. 27 Installing Front Output Seal. Fig. 28 Sector W/shaft. Fig. 29 Synchronizer Hub Assembly & Mode Fork. Fig. 30 Oil Pump Pickup Screen Doweled Case Holes.