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99 Tracer (3rd generation) 5 speed manual.

Differential making lots of noise again. Good source for rebuild kits, or reman transmission?

Might consider rebuilding the differential only as the transmission shifts quite nicely. Synchros are broken in. If the differential gear and its drive gear are badly worn where to get new?

I saw kits for $150 to $200 and reman trans for around $1000. Don't know who to trust for a reman. Repair shop wants about $3000 to do the job which is probably reasonable. I have rebuilt manual transmissions in the past, decades ago. Have the Ford Escort/Tracer factory shop manual.

Have bottom crossmember off for something else. able to remove the transmission that route?
 

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I haven't rebuilt one of these, but I've done many rear wheel drive transmissions.
I imagine with your experience and the shop manuals you shouldn't have serious trouble, there might be a couple special tools that would be useful to have.

A solvent tank and good work area would be really helpful.
 

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My escorts are all the 2nd gen LX kind. With those, the manual transmission can be taken out from the bottom, but it involves supporting the engine somehow and letting it tilt down slightly. The 5-speed cant come out the top, as the engine bay isnt wide enough for the trans input shaft to clear the flywheel, so the only -other- removal route is to hoist out the engine and trans still bolted together. This is how I prefer to do it, since with cars as old as mine are, there is always useful work to do on the engine and in the engine bay, once the engine is out.
Examples of this are freeing up the four nuts holding the power steering rack to the subframe (the nuts get crusty with time), and replacing the freeze plugs on the block. I think the 3rd gen are the same as the 2nd gen here. There are 5 freeze plugs on the block; 4 of them being 1-3/8" and located on the sides of the block, and a single larger one of 2-3/16" located on the end of the block. That one can only be reached once the trans and flywheel are removed.
 

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One specific tool is a sleeve that goes over the splines in order to put a wrench on it and hold the shaft when taking off the nut that is under the black access cover that also covers 5th gear I believe. I can tell you that the sleeve tool thing is definitely different between 2nd and 3rd gen escorts.
 

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So had the car running and driving with a new speedo sensor on the way. Go to install the new speedo sensor and now second gear and fourth won’t engage. Come to fine that the speedo sensors plastic gear and metal clip fell off. So I tried to fish it out but it’s too deep to get to. Anyone have any knowledge on disassembling this trans I have a Haynes exploded diagram of the trans but y’all’s advice is better.
 

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Get a more powerful magnet on some kind of a probe tool. The best magnets are made of neodymium, but be sure you have the magnet -securely- attached to a string or cord. Then be able to turn the differential, which means having the front wheels off the ground. The plastic gear will likely get smashed up without hurting the steel parts of the differential - though you might be picking parts out with long tweezers.

Disassembling the trans involves the serious first step of getting it out of the car. This involves either lowering it out the bottom (after disconnecting from the engine), or hoisting the entire engine and transmission up and out - still bolted together. Actually getting to where you can take the differential apart is after you have unbolte the two halves of the trans case.
The ford service manual for the car should have the interior views.
 

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Get a more powerful magnet on some kind of a probe tool. The best magnets are made of neodymium, but be sure you have the magnet -securely- attached to a string or cord. Then be able to turn the differential, which means having the front wheels off the ground. The plastic gear will likely get smashed up without hurting the steel parts of the differential - though you might be picking parts out with long tweezers.

Disassembling the trans involves the serious first step of getting it out of the car. This involves either lowering it out the bottom (after disconnecting from the engine), or hoisting the entire engine and transmission up and out - still bolted together. Actually getting to where you can take the differential apart is after you have unbolte the two halves of the trans case.
The ford service manual for the car should have the interior views.
I actually took the trans out today. Took me a couple hours. Just wondering if theirs anything specific I should watch for when splitting the case. Thanks for your advice.
 

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I would avoid removing the bolts on the sides of the case, until you know what they are holding, and how to get them back lined up.
 

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"]And that tool is essential; for loosening ad torquing up again."

Only concerninjg the F-trans in the 91'-96's LX, I took the old friction disk and screwed a 2x4x12" to it, you drop the disk on the splines, and position the wood to occupy the bellhousing where the starter would be, and drive some drywall screws to join both.

Also, maybe check this guy out
there's a couple of others on utube for Mazda transaxle
 
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