Assembly

1. Inspect the mainshaft and all mainshaft components for wear or damage.

2. CAUTION: Do not reassemble the mainshaft dry. Apply lubricant throughout the assembly procedure.

Lubricate all mainshaft components with the recommended Transmission lubricant, MERCON(R) Multi-Purpose Automatic Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON(R).





3. Position the mainshaft in the Axle Bearing Seal Plate with the input end facing upward.





4. Install the mainshaft first gear needle bearing.





5. Install first gear and the first gear synchronizer ring.





6. Install the first and second synchronizer body.
^ The numbers on the synchronizer body must face upward.
^ Make sure to align the notches on the synchronizer body with the tabs on the synchronizer ring.





7. Install the synchronizer sliding sleeve, then pushing down on the sleeve, engage first gear.
^ Install the synchronizer sliding sleeve with the bevel edge against first gear.





8. Install the detent springs and the detents.





9. Install a new snap ring.
^ Install the snap ring with the small holes facing upward.
^ The snap ring is a selective fit. The correct snap ring should completely fill the groove when seated. Using a feeler gauge, check the clearance between the snap ring and the synchronizer body. Clearance should not be greater than 0.1 mm (0.004 inch).





10. Install the second gear synchronizer ring.
^ Move the synchronizer sliding sleeve to the center position.





11. Install the mainshaft second gear needle bearing.





12. Install second gear.





13. Remove the mainshaft third gear thrust washer from the Gear/Bearing Heater and install it on the mainshaft.
^ Using a suitable driver, tap or press the thrust washer down until it is seated against the stop.





14. Remove the mainshaft third gear bushing from the Gear/Bearing Heater and install it on the mainshaft.
^ Using a suitable driver, tap the spacer down until it is seated against the stop.

15. Note: Let the mainshaft third gear bushing cool down for 2-4 minutes before trying to install the mainshaft needle bearing.





Install the mainshaft third gear needle bearing.





16. Install third gear and the third gear synchronizer ring.





17. Remove the third and fourth gear synchronizer body from the Gear/Bearing Heater and install it on the mainshaft.
^ Install the synchronizer body with the part numbers facing upward,





18. Install a new snap ring.
^ Install the snap ring with the small holes facing upward.
^ The snap ring is a selective fit. The correct snap ring should completely fill the groove when seated.





19. Install the synchronizer sliding sleeve, then push it downward to engage third gear.





20. Install the detent springs and the detents.





21. Install the fourth gear synchronizer ring.
^ Move the synchronizer sliding sleeve to the center position.

22. CAUTION: Drive the input shaft pocket bearing onto the mainshaft by the inner race only. Using the outer race will damage the bearing.





Remove the input shaft pocket bearing from the Gear/Bearing Heater and install it on the mainshaft.
^ Using a suitable driver, tap the bearing down until it is seated against its stop.
23. Reposition the mainshaft in the Axle Bearing Seal Plate with the output end facing upward.





24. Install the mainshaft reverse gear needle bearing.





25. Install the reverse gear.
^ The gear clutching teeth must face upward.





26. Install the reverse gear synchronizer ring.








27. Remove the fifth and reverse synchronizer body from the Gear/Bearing Heater and install it on the mainshaft.
^ The numbers on the synchronizer body must face upward.
^ The side with the shoulder (deeper hub) faces downward. Make sure to align the notches on the synchronizer body with the tabs on the synchronizer ring.





28. Install a new snap ring.
^ Install the snap ring with the small holes facing upward.
^ The snap ring is a selective fit. The correct snap ring should completely fill the groove when seated.





29. Install the synchronizer sliding sleeve, sliding the sleeve down to engage the clutching teeth of the reverse gear.





30. Install the detent springs and the detents.





31. Install the fifth gear synchronizer ring.





32. Install the mainshaft fifth gear split needle bearing.





33. Install fifth gear.

34. CAUTION: Drive the output shaft rear bearing onto the mainshaft by the inner race only. Using the outer race will damage the bearing.





Remove the output shaft rear bearing from the Gear/Bearing Heater and Install it on the mainshaft.
^ Make sure the bearing is seated against the stop.





35. Note: The snap ring is used on 4-wheel drive vehicles only.

Install a new snap ring.
^ Install the snap ring with the small holes facing upward.
^ The snap ring is a selective fit. The correct snap ring should completely fill the groove when seated.

36. Note: The Transmission must be in the neutral position before final assembly.

Place the mainshaft in the neutral position.
^ Hold down the input shaft and pull up on the third and fourth synchronizer sliding sleeve to the neutral position.
^ Lift up on the first and second synchronizer sliding sleeve to the neutral position.

37. CAUTION: Do not drive against the bearing cone. Drive against the inner race only.





Remove the input shaft bearing from the Gear/Bearing Heater and install the bearing. Using a suitable driver, make sure the bearing is seated against its stop.





38. Using the special tool, install the input shaft rear oil dam.
^ Make sure the input shaft rear oil dam is completed seated.
39. Install the input shaft
^ Fill the input shaft pocket with a suitable engine assembly white grease.

40. Note: If the following axial gear clearances are not within specification, it will be necessary to disassemble and reinspect.





Using the special tools, check the axial gear clearance at the mainshaft first gear.





41. Using the special tools, check the axial gear clearance at the mainshaft second gear.





42. Rotate the mainshaft with the input shaft facing downward. Using the special tools, check the axial gear clearance at the mainshaft third gear.





43. Using the special tools, check the axial gear clearance at the mainshaft reverse gear.





44. Using the special tools, check the axial gear clearance at the mainshaft fifth gear.