Assembly

Special Tools:

1. Position the main shaft and counter shaft assembly in the holding fixture.





2. Install the center plate on the main shaft and counter shaft.





3. Install the 5th gear synchronizer hub.
^ Install the synchronizer hub.





4. Install the sliding sleeve.
^ Install the sliding sleeve and the three pressure pieces and springs.





5. Install the bearing sleeve.
^ Use a bearing/gear heater to heat the bearing sleeve to 130°C (250°F).
^ Install the bearing sleeve.





6. Install the needle bearing.





7. Install the 5th gear, thrust washer and snap.





8. Install the gear and sliding sleeve needle bearing.
9. Install the synchronizer hub.
^ Use a gear/bearing heater to heat the synchronizer housing to 130°C (250°F).
^ Install the synchronizer hub.

10. Install the sliding sleeve and the three pressure pieces and springs.





11. Install the bearing sleeve.
^ Use a gear/bearing heater to heat the bearing sleeve to 130°C (250°F).
^ Install the bearing sleeve.





12. Install the needle bearing and the reverse gear.





13. Install the thrust washer.
^ Use a gear/bearing heater to heat the thrust washer to 130°C (250°F).
^ Install the thrust washer.





14. Install the output bearing.
^ Use a gear/bearing heater to heat the bearing to 130°C (250°F).
^ Install the output bearing.

15. Position the shift forks on the sliding sleeves.





16. Install the shift rail through the center plate and the shift forks.





17. Install the 1/2-3/4 rail driver roll pin.
1 Engage 2nd gear.
2 Install the roll pin.





18. Install the center rail driver roll pin.
19. Install the shift fork roll pins.
20. Position the front transmission case on the floor.

21. CAUTION: Do not use a silicone sealing compound.

NOTE: Do not wait longer than 10 minutes to tighten the bolts, due to the rapid curing time of the sealant.

Thinly coat the sealing surface of the front case and the center plate with Gasket Maker E2AZ-19562-B or equivalent meeting Ford specification WSK-M2G348-A5.





22. Use the lifting tool to position the center support assembly into the front case.
23. Install the bolts.

24. CAUTION: Do not use a silicone sealing compound.

NOTE: Do not wait longer than ten minutes to tighten the 19 bolts due to the rapid cure time of the sealant.

Thinly coat the sealing surface of the rear case and the center plate with Gasket Maker E2AZ-19562-B or equivalent meeting Ford specification WSK-M2G348-A5.





25. Install the 19 bolts.
26. Install the output flange.
^ Install the output flange.
^ Install the nut.