Assembly
ASSEMBLYTransmission
Special Tools:
Special Tool(s)
Assembly
1. Install the countershaft cluster gear.
2. Position the input shaft.
3. NOTE: Make sure the fourth gear synchronizer blocking ring is in place.
Install the output shaft.
4. Mate the input shaft and output shaft together.
5. Install the countershaft pilot bearings on both ends.
6. Install the output shaft rear bearing and input shaft bearing.
7. NOTE: Install the rear bearing retainer with the arrow pointing to the top of the case.
Install the rear bearing retainer.
1. Position the rear bearing retainer.
2. Install the bolts.
8. NOTE: If any related parts (such as the output shaft and bearings) have been installed new, carry out the shim thickness selective procedure.
Using the special tool, install the front cover oil baffle.
9. Position the transmission with the bell housing facing up.
10. Using the special tool, measure the input shaft bearing race depth.
^ Record the reading on line 2 of the selective shim equation chart.
11. Using the special tool, measure the front bearing retainer depth.
^ Record the reading on line 1 of the selective shim equation chart.
12. Calculate and select the correct output shaft shim. Refer to the Output Shaft Shim Selective Chart.
Selective Shim Equation Chart
Output Shaft Shim Selective Chart
13. Using the special tool, measure the countershaft bearing depth.
^ Record the reading on line 1 of the countershaft spacer equation chart.
14. Using the special tool, measure the Countershaft bearing retainer depth.
^ Record the reading on line 2 of the Countershaft spacer equation chart.
15. Calculate and select the correct Countershaft spacer. Refer to the Countershaft Spacer Selective Chart.
Countershaft Spacer Equation Chart
Countershaft Spacer Selective Chart
16. NOTE: If necessary, apply a light coat of grease to the countershaft spacer, shim and fluid baffle.
Position the bearing shim, the fluid baffle, and the countershaft spacer onto the front bearing retainer.
^ Using Gasket Maker F8AZ-19B508-AB or equivalent meeting Ford specification WSK-M2G348-A5, apply a thin coat to the sealing surface of the case and the front bearing retainer.
17. NOTE: To prevent damage to the fluid seal lip during assembly, tape the input shaft splines.
Install the front bearing retainer.
18. Position the fluid passage.
19. Install the fluid passage bolt.
20. Install the output shaft fifth gear.
21. Install the locking ball.
22. Install the race and the fifth gear split bearing on the countershaft.
23. Install the countershaft fifth gear.
24. Install the fifth/reverse shift lever through the case.
25. Install the counter lever shaft assembly.
^ Install the plate with the arrow pointing downward. The chamfer points upward on the shaft assembly.
26. Install the countershaft fifth gear synchronizer blocking ring.
27. NOTE: The reference mark on the synchronizer sleeve must face toward the reverse gear.
Install the fifth/reverse shift rail, the shift fork, and the synchronizer as an assembly.
28. Install the fifth/reverse gear shift rail bolt.
29. Install the synchronizer split washer.
30. Using a feeler gauge, check the clutch hub end play.
^ If the clutch hub end play is not within specification, select and install the correct split washer.
Spilt Washer Select Chart
31. Install the thrust washer.
32. Install the countershaft reverse gear.
1. Install the reverse synchronizer blocking ring.
2. Install the two countershaft reverse gear bearings.
3. Install the countershaft reverse gear.
33. Measure the countershaft reverse gear end play.
^ Install the thrust washer and hold it against the shoulder on the countershaft while checking the end play.
^ Determine the correct thrust washer to obtain the correct end play.
Thrust Washer Select Chart
34. Install the output shaft spacer.
35. Install the output shaft reverse gear.
36. Install the reverse idler gear.
37. NOTE: Reverse idler shaft bolt must be installed within four minutes after applying the pipe sealant with Teflon.
Install the reverse idler shaft bolt.
^ Apply Pipe Sealant with Teflon D8AZ-19554-A or equivalent meeting Ford specification WSK-M2G350-A2 to reverse idler shaft bolt threads.
38. Using the special tools, install the output shaft rear bearing.
39. Install the thrust washer and the countershaft rear bearing.
40. Lock the transmission into first and third gear.
41. Using the Transmission Shaft Locknut Socket, install a new output shaft rear bearing lock nut.
42. Install a new countershaft lock nut.
43. Using the special tool, stake the output shaft rear bearing lock nut and the countershaft lock nut.
44. Install a new tone wheel, the lock bolt and the tone wheel snap ring.
45. Install the extension housing.
^ Apply Gasket Maker F8AZ-19B508-AB or equivalent meeting Ford specifications WSK-M2G348-A5 to the mating surfaces before installing.
46. Using the special tool, install the extension housing seal.
47. Place the synchronizer sleeves in neutral.
48. Install the case cover with a new gasket.