Assembly

Special Tools:

Special Tools:

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 bearing.





6. Install the output shaft rear 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 replaced, perform the shim thickness selective procedure.

Use (A) Bell Housing Seal Replacer to install the (B) front cover oil baffle.
9. Position the transmission with the bell housing facing up.





10. Use (B) Depth Micrometer to measure dimension (A) input shaft bearing race depth.
- Record dimension (A) on line 2 of the selective shim equation chart.





11. Use (A) Depth Micrometer to measure dimension (B) front bearing retainer depth.
- Record dimension (B) on line 1 of the selective shim equation chart.

Output Shaft Shim Selection Chart:

12. Select the proper output shaft shim.





13. Use (A) Depth Micrometer to measure dimension (C) countershaft bearing.
- Record dimension (C) on line 1 of the countershaft spacer equation chart.





14. Use (A) Depth Micrometer to measure dimension (D) countershaft bearing retainer depth.
- Record dimension (D) on line 2 of the countershaft spacer equation chart.
15. Select the proper countershaft spacer.












16. NOTE: If necessary, apply a light coat of grease to the countershaft spacer, shim and fluid baffle.

Position the (A) bearing shim, the (B) fluid baffle, and the (C) countershaft spacer onto 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.
1 Position the front bearing retainer.
2 Install the bolts.





18. Position the fluid passage.





19. Install the fluid passage bolt.





20. Install the output shaft Fourth Gear (4GR).





21. Install the (A) race and the (B) fifth speed gear split bearing on the countershaft.





22. Install the countershaft fifth speed gear.





23. Install the counter lever shaft assembly.
1 Position the counter lever shaft and plate.
2 Install the counter lever shaft bolt.





24. Install the 5th reverse shift lever.
1 Position the 5th reverse shift lever.
2 Install the 5th reverse shift retaining ring.





25. Install the countershaft fifth gear synchronizer blocking ring.





26. NOTE: The reference mark on the synchronizer sleeve must face toward the reverse gear.

Install the (A) fifth/reverse shift rail, the (B) shift fork, and the (C) synchronizer.





27. Install the fifth/reverse shift rail bolt.





28. Install the synchronizer split washer.





29. Check clutch hub end play.

Spilt Washer Select Chart:

- If clutch hub end play is not within specification, select and install the correct split washer.





30. Install the countershaft reverse gear.
1 Install the countershaft reverse gear.
2 Install the two countershaft reverse gear bearings. Install the reverse synchronizer blocking ring.





31. 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.

Thrust Washer Select Chart:

- Determine the correct thrust washer to obtain the correct end play.





32. Install the output shaft spacer.





33. Install the output shaft reverse gear.





34. Install the reverse idler gear and bushing.





35. NOTE: Reverse idler shaft bolt must be installed within four minutes after applying silicone.

Apply Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A to reverse idler shaft bolt threads and install the reverse idler shaft bolt.





36. Use (A) Gear Replacing Spacer, (B) Shaft Collar, (C) Shaft Sleeve Replacer, (D) Remover/Replacer Tube, (E) nut and (F) washer to install the (G) output shaft rear bearing.





37. Install the (A) thrust washer and (B) countershaft rear bearing.





38. Lock the transmission into first and third gear.





39. Use Mainshaft Locknut Wrench to install a new output shaft rear bearing lock nut.





40. Install a new countershaft locknut.





41. Use (A) Countershaft Locknut Staking Tool to stake the (B) output shah rear bearing lock nut and the (C) countershaft locknut.

42. NOTE: Extension housing must be installed within four minutes after applying silicone.

Apply a small bead of Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A to the extension housing mating surface.





43. Install the extension housing.
1 Position the extension housing.
2 Install the bolts.





44. Use Extension Housing Seal Replacer to install the extension housing seal.





45. Place the synchronizer sleeves in neutral.

46. NOTE: Case cover must be installed within four minutes after applying silicone.

Apply a small bead of Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A to the case cover mating surface.





47. Install the case cover.
1 Position the case cover.
2 Install the bolts.