Assembly

Special Service Tool(s) Required:

1. Mount transmission case onto Bench Mounted Holding Fixture T57L-500-B as shown.






2. Rotate case (7005) and holding fixture to upright position. Using petroleum jelly, lubricate bearing races and main shift rail bushing in case.






3. Install main shift rail subassembly onto mainshaft

NOTE: Shift forks must align with synchronizer sleeve grooves.






4. Simultaneously install main shift rail and mainshaft subassembly into case from the top.






5. Install fourth gear blocker ring onto fourth gear synchronizer assembly while aligning pockets in blocker ring with inserts of synchronizer assembly.

NOTE: Soak blocker ring in MERCON� Multi-Purpose Automatic Transmission Fluid or equivalent for ten minutes prior to installation. MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4.






6. Using Torx 40 bit, install new main shift rail interlock bolt or apply Pipe Sealant with TEFLON� D8AZ-19554-A or equivalent meeting Ford specification WSK-M2G350-A2 and ESR-M18P7-A to threads of previously used main shift rail interlock bolt. Tighten to 20-34 Nm (15-25 lb-ft).

NOTE: Verify that interlock bolt is in the interlock track on the interlock collar.






7. Lift mainshaft subassembly approximately 25 mm (1 inch). Install countershaft cluster gear from front as shown.

NOTE:
- Do not lift mainshaft subassembly by third/fourth synchronizer assembly.
- After installation of countershaft cluster gear (7113), slowly spin mainshaft/countershaft to confirm free rotation.






8. Install reverse gearshift lever (7K002) and reverse gearshift lever pivot pin bolt. Tighten bolt to 34-47 Nm (25-35 ft. lbs.).

NOTE: Use new pivot pin bolt or apply Pipe Sealant with TEFLON v D3AZ-19554-A or equivalent meeting Ford specification WSK-M2G350-A2 and ESR-M13P7-A on old bolt threads.






9. Install reverse gearshift lever retaining clip onto reverse shift lever anchor bolt as shown.






10. Install fifth reverse shift rail. Rotate to insert pin on shift rail in track in fifth/reverse gearshift lever.

NOTE: Fifth/reverse shift rail pin must align with track in fifth/reverse gearshift lever.






11. Using petroleum jelly, lube input shaft support bearing and input shaft pocket bearing. Install input shaft onto output shaft.






12. Apply petroleum jelly to bearing cups. Install flywheel housing to case taking care to align shift rails into appropriate shift rail bore.

CAUTION: Care should be taken not to damage input shaft seal when installing flywheel housing (6392).






13. Install four opposing housing-to-case bolts. Tighten to 34 Nm (25 ft. lbs.).






14. Spin output shaft to make sure it turns freely. Mount Dial Indicator TOOL-4201-C or equivalent as shown. Apply upward load to rear of output shaft. Record indicated end clearance. Clearance must be between 0.025 mm (0.0009 inch) tight and 0.051 mm (0.0020 inch) loose.
^ If required, select appropriate shim thickness to correct end clearance. Shim at the input shaft bearing pocket.






15. Rotate transmission so rear faces upward, spin countershaft to make sure it turns freely. Mount dial indicator as shown. Apply upward load on rear of countershaft. Record indicated end clearance. Clearance must be between 0 mm (0 inch) tight and 0.076 mm (0.0030 inch) loose. If required, select appropriate shim thickness to correct end clearance. If end clearance of countershaft or mainshaft does not require correction, proceed to Step 18.






16. If shimming is required for countershaft, remove flywheel housing from case. Remove outer bearing cup from flywheel housing. Install appropriate shim into cup pocket and install cup.
17. If shimming is required for mainshaft, remove flywheel housing. Remove input shaft pocket support outer bearing cup and shim. Install appropriate shim in input shaft pocket. Install cup.
18. Apply a 3.2 mm (1/8-inch) bead of Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A and ESE-M4G195-A to mating surfaces of flywheel housing and case. Apply petroleum jelly to bearing races in flywheel housing. Place flywheel housing on case. Install twelve bolts retaining flywheel housing to case. Tighten to 20-34 Nm (15-25 ft. lbs.) using star-pattern sequence.

NOTE: Care should be taken not to damage input shaft seal when installing flywheel housing.






19. Place transmission on bench and move mounting fixture adapter from rear of case to flywheel housing as shown.






20. Slide fifth speed drive gear onto countershaft with synchronizing cone to the rear of countershaft cluster gear.






21. Install fifth-speed blocker ring onto fifth-speed gear on countershaft cluster gear.

NOTE: Soak blocker ring in MERCON� Multi-Purpose Automatic Transmission Fluid or equivalent for a minimum of ten minutes.






22. Install fifth/reverse synchronizer sleeve and reverse synchronizer sleeve onto fifth/reverse shift fork. Simultaneously slide onto fifth/reverse shift rail, mainshaft and countershaft hub.

NOTE: Fifth/reverse synchronizer struts must align with X on synchronizer sleeve.






23. Using Remover Tube T77J-7025-B and Replacer/Adapter T76P-7025-A, press fifth/reverse synchronizer hub onto countershaft cluster gear as shown.

NOTE: The fifth/reverse synchronizer hub is reversible. Verify synchronizer struts are indexed with pockets in fifth gear blocker ring during hub installation.






24. Install reverse gear synchronizer hub onto output shaft as shown.

NOTE: Hub splines must face toward rear.






25. Align fifth/reverse shift fork and shift rail. Install split pin through both.








26. Install retaining ring onto countershaft cluster gear behind fifth/reverse synchronizer assembly.






27. Install reverse synchronizer hub retaining ring onto output shaft.






28. Install reverse driven gear bearing spacer onto output shaft.






29. Using petroleum jelly, lube then install reverse gear mainshaft bearing onto output shaft.






30. NOTE: Index pockets on blocker ring to inserts of synchronizer hub. Soak blocker ring in MERCON(r) Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or equivalent for ten minutes prior to installation.

Install reverse countershaft blocker ring onto reverse synchronizer assembly.






31. Install reverse drive gear onto countershaft cluster gear as shown.






32. Install reverse gear spacer onto countershaft cluster gear.









33. Install reverse drive gear retaining ring onto countershaft cluster gear as shown.






34.NOTE: Clutching teeth must face synchronizer (7124).

Install reverse driven gear over needle bearing on output shaft.






35. Install reverse gear select spacer onto output shaft.





36. Install reverse gear spacer retaining ring onto output shaft.









37. Pull reverse speed gear toward rear of shaft until it bottoms on spacer and snap ring. Using a feeler gauge, verify clearance between reverse speed gear and reverse synchronizer hub is 0.05 mm (0.002 inch) to 0.30 mm (0.012 inch). If not within specifications, remove snap ring and spacer. Select appropriate spacer and install spacer and snap ring.






38. Place new output shaft support bearing onto output shaft. Press into place using Remover/Replacer Tube T75L-7025-B and Replacer/Adapter T96P-7025-A and threader rod.









39. Install output shaft bearing retaining ring onto output shaft.









40. Install speedometer drive gear front retaining ring onto output shaft.






41. NOTE: Chamfer on internal splines of speedometer drive gear (17285) must face down.

Install speedometer drive gear onto output shaft.









42. Install speedometer drive gear rear retaining ring onto output and fifth gear drive shaft (7061).






43. Apply an even 3.2 mm (1/8 inch) bead of Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A and ESE-M4G195 to the extension housing mating surface of transmission case.






44. NOTE: A liberal application of petroleum jelly to guide plate in extension housing will aid in keeping the detent ball in position during this step.

Hold in place the detent ball, detent spring and gearshift offset lever (7F018) into neutral position at the three/four plane of detent plate in extension housing (7A039). Place extension housing over output and fifth gear drive shaft and main shift rail approximately 51 mm (2 inch) from case. Simultaneously lower gearshift offset lever onto main shift rail and extension housing onto case.









45. Install transmission identification tag in position shown. Install eleven extension housing retaining bolts and tighten to 20-34 Nm (15-25 ft. lbs.).






46. Align offset lever split pin hole with hole in shift rail. Install split pin.






47. NOTE: Shifter ball must align with socket in offset lever.

Apply 3.2 mm (1/8 inch) bead of Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A and ESE M4G195-A to shifter plate mating surface of extension housing turret. Install shifter plate and four retaining bolts. Tighten to 15-27 Nm (11-20 ft. lbs.).






48. Apply Pipe Sealant with Teflon(r) D8AZ-19554-A or equivalent meeting Ford specifications WSK-M2G350 and ESR-M18P7-A to threads of case plug(7A010). Install case plug and tighten to 11-24 Nm (8-18 lb-ft).






49. Apply Pipe Sealant with Teflon D8AZ-19554-A or equivalent meeting Ford specifications WSK-M2G350-AZ and ESR-M1SP7-A to threads of backup lamp switch (15520). Install and tighten to 27-47 Nm (20-35 ft. lbs.).






50. Using petroleum jelly, lube then install full fill seal over output shaft with chamfer facing forward until rear of seal is approximately 25 mm (1 inch) from the rear of the output shaft.






51. Using a 3/8 inch driver ratchet and extension, remove fill hole case plug. Add 3.1 L (107 ounces) to 3.3L (111 ounces) MERCON(r) Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or equivalent.

Apply Pipe Sealant with Teflon D8AZ-19554-A or equivalent meeting Ford specifications WSK-M2G350-A2 and ESR-M18P7-A to threads of fill hole case plug. Reinstall and tighten to 11-24 Nm (9-17 lb-lbs).