Part 2

Transmission

Transmission Internal Components - Disassembled View

Transmission Shift Components - Disassembled View

NOTE: Transmission fluid usage:
- Gas engines use MERCON(R) V Automatic Transmission Fluid.
- Diesel engines use Motorcraft(R) Full Synthetic Fluid.

31. Using a 5 mm (3/16 in) punch, align the roll pin hole with the top hole of the shift fork. Install the double roll pin in the lower hole, then install a roll pin in the upper hole.
- Make sure the slot of the roll pin is facing away from the shift rail.

32. Install the 4 shift detent springs and 4 new detent plugs.
- Apply gasket maker to the detent plugs before installing.

33. Install the main shift rail, aligning the center of the interlock driver with the center of the interlock plate.
- The part numbers on the main shift rail, shift position block and shift finger face the output side of the transmission. The roll pin groove on the main shift rail with the shorter distance from the end faces the output end.

34. Install the lower shift finger and a new large roll pin, then install a new small roll pin.
- Make sure the lower shift finger cup is down.

- Install the large roll pin with the opening away from the gearset.

- Make sure the center of the interlock driver is aligned with the center of the interlock plate before installing the small pin.

- Install the small roll pin with the opening 180 degrees from the opening in the large roll pin. The roll pin should extend equally from both sides when correctly installed.

35. Install the main shift rail driver and a new large roll pin, then install a new small roll pin.
- Install the large roll pin with the opening away from the gearset.

- Install the small roll pin with the opening 180 degrees from the opening in the large roll pin.

36. NOTE: Only install the bearing cups in the main case. The following bearing preload adjustment procedure will determine the thickness of the shim to be used.

NOTE: For vehicles equipped with gasoline engines, the transmission must be elevated 50-101 mm (1.968-3.976 in), to prevent damage to the input shaft.

Place the main case on the floor. Align the oil pump center shaft with the slot in the countershaft.

37. NOTE: Do not apply sealer at this time.

NOTE: Do not damage the input shaft when removing it from the Gear Pack Fixture.

NOTE: To aid installation, have an assistant lower the assembly while another guides the assembly into the main case.

Using a suitable lifting device, a suitable chain and 2 S-hooks, lift the intermediate housing and gear assembly into the case.

- Using the index mark made on the countershaft, make sure the oil pump center shaft is aligned with the slot on the countershaft.

- Lightly tap the intermediate housing onto the transmission case.

38. Install the intermediate housing-to-case bolts.
- Tighten to 23 Nm (17 lb-ft).

39. Install the Dial Indicator Gauge with Holding Fixture and the Clutch Housing Gauge to measure countershaft clearance.
- Mount the Holding Fixture to the intermediate housing.

- Install the Dial Indicator Gauge. Make sure the indicator is off center on the end of the countershaft.

- Zero the Dial Indicator Gauge.

40. NOTE: The Front Wheel Hub Remover/Installer is installed on the Power Take-Off (PTO) opening.

Using the Front Wheel Hub Remover/Installer, measure for countershaft clearance.

- Lift up on the 3rd gear counter.

- Observe the Dial Indicator Gauge reading.

- Add preload specification 0.02 mm (0.0007 in) and 0.09 mm (0.003 in) to the Dial Indicator Gauge reading to determine shim thickness range. Countershaft clearance + 0.02 mm (0.0007 in) Preload = Shim size. Countershaft clearance + 0.09 mm (0.003 in) Preload = Shim size. Choose the shim between the calculated values for the correct preload.

41. Install the Dial Indicator Gauge with Holding Fixture and the Clutch Housing Gauge to measure mainshaft clearance.
- Mount the Holding Fixture to the intermediate housing.

- Install the Dial Indicator Gauge. Make sure the indicator is off center on the end of the mainshaft.

- Zero the Dial Indicator Gauge.

42. Lifting up on the mainshaft, measure the mainshaft clearance.
- Lift up on the low gear.

- Observe the Dial Indicator Gauge reading.

- Add preload specification 0.02 mm (0.0007 in) and 0.09 mm (0.003 in) to the Dial Indicator Gauge reading to determine shim thickness. Measure the thickness of the input shaft oil dam bearing ring at 3 places and subtract the highest dimension. Mainshaft clearance (-) the thickness of the oil dam + 0.02 mm (0.0007 in) Preload = Shim size. Mainshaft clearance (-) the thickness of the oil dam + 0.09 mm (0.003 in) Preload = Shim size. Choose the shim between the calculated values for the correct preload.

43. Remove the special tools, then remove the intermediate housing-to-case bolts.

44. Using a suitable lifting device, a suitable chain and 2 S-hooks, lift the intermediate housing and gear assembly out of the case.
- Place the S-hooks in the area where the bolts were removed.

45. Using the Front Wheel Hub Remover/Installer and the Input Shaft Bearing Cup Remover, remove the input shaft bearing cup.

46. Using the Slide Hammer with the Bearing Cup Remover, remove the countershaft bearing cup.

47. NOTE: Use a Heat Gun on the case bearing cup area to aid installation.

Install the new shim, the new input shaft oil dam bearing ring and the oil trough into the bearing cup bore, then using the Input Shaft Bearing Cup Installer with the Handle, install the input shaft bearing cup.

- Using the clearance measurement plus the preload, select the appropriate shim and input shaft oil dam bearing ring.

48. NOTE: Use a Heat Gun on the case bearing cup area to aid installation.

Install the new shim, then using the Centerplate Front Bearing Cup Installer and the Handle, install the countershaft bearing cup.

- Using the clearance measurement plus the preload, select the appropriate shim.

49. NOTICE: Do not use a silicone sealing compound or damage to the components can occur.

NOTE: Use an oil stone or sanding block to clean the intermediate plate and main case mating surfaces.

NOTE: Do not wait longer than 10 minutes to tighten the 2 bolts due to the rapid cure time of the sealant.

Thinly coat the rear sealing surface of the case and the front sealing surface of the intermediate housing with gasket maker.

50. NOTE: For vehicles equipped with gasoline engines, the transmission must be elevated, 50-101 mm (1.968-3.976 in), to prevent damage to the input shaft.

NOTE: To aid installation, have an assistant lower the assembly while another guides the assembly into the case.

Install the intermediate housing and gear assembly into the case.

- Using the index mark made on the countershaft, make sure the oil pump center shaft is aligned with the slot on the countershaft.

- Lightly tap the intermediate housing onto the transmission case.

51. Install the intermediate housing-to-case bolts.
- Apply threadlock and sealer to the intermediate housing-to-case bolts.

- Tighten to 23 Nm (17 lb-ft).

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

Thinly coat the rear sealing surface of the intermediate housing and the extension housing with gasket maker. Install the extension housing and the 19 extension housing-to-case bolts.

- Tighten to 23 Nm (17 lb-ft).

53. Apply threadlock and sealer to the threads of the main shift detent. Install the detent plunger and the main shift detent.
- Tighten to 65 Nm (48 lb-ft).

54. NOTE: Tighten the bolts in a cross pattern.

Apply threadlock and sealer to the threads of the PTO cover plate bolts. Install a new gasket and the PTO cover.
- Tighten to 38 Nm (28 lb-ft).

55. NOTE: The tool listed is for gasoline equipped vehicles only. To install the seal for diesel equipped vehicles, use a suitable 1.75 inch ID x 10 inch pipe. Make sure the seal is flush with the transmission case.

Using the Input Shaft Oil Seal Installer, install a new input oil seal.

- Coat the inner diameter of the new input oil seal with manual transmission fluid.

56. Apply threadlock and sealer to the threads of the guide tube bolts. Install the guide tube.
- Tighten bolts to 23 Nm (17 lb-ft).

57. Install the release lever and clutch release hub and bearing.
- Lubricate the ball stud and the clutch release lever. Only apply grease where the clutch release lever comes in contact with the pivot and the release hub and bearing.

58. Using the Output Shaft Oil Seal Installer (4x2) 308-382 for RWD or Output Shaft Oil Seal Installer (4x4) 308-383 for 4WD, install a new output oil seal.

59. NOTE: This step is for 2-Wheel Drive (2WD) vehicles only.

Apply threadlock 262 to the threads of the transmission flange locknut. Using the Drive Pinion Flange Holding Fixture and the Mainshaft Locknut (36-mm) Socket, install the transmission flange and a new output flange locknut.

- Tighten to 330 Nm (244 lb-ft).

60. Install the shift housing and the 4 shift housing-to-case bolts.
- Tighten to 23 Nm (17 lb-ft).

- Shift the transmission through all gears to verify gears shift correctly.

61. Check transmission preload. Shift the transmission into reverse and rotate the mainshaft.
- Drag torque should be 2-8 Nm (18-70 lb-in).

62. Remove the shift housing-to-case bolts and the shift housing for installation.