Ford RAD (4-Speed)

DISASSEMBLY
1. Drain lubricant from transmission by removing extension housing lower bolt.

RAD Four Speed Transmission Disassembled. (Typical):

2. Drive access plug from rear of extension housing and remove offset lever assembly.
3. Remove extension housing from case.
4. Remove transmission cover, shifter fork and shift rod assembly.
5. Remove front bearing retainer and gasket.
6. Remove spring clip securing reverse lever assembly to pivot bolt, then the pivot bolt and reverse level assembly.
7. Support countershaft gear with a wire hook. Drive a dummy countershaft through front of case until cluster gear drops to bottom of case, then remove counter shaft through rear of case and lower cluster gear to bottom of case.

Removing Input Shaft. RAD Four Speed Transmission:

8. Remove input shaft.
9. Remove speedometer drive gear snap ring, slide gear off output shaft and remove lock ball from output shaft.
10. Remove output shaft bearing retaining snap ring. Using the outer snap ring, pull output shaft bearing from case and off shaft, then remove output shaft assembly through top of case.
11. Slide reverse idler gear shaft through rear of case, then remove reverse gear and cluster gear from bottom of case.

ASSEMBLY
1. Place reverse idler gear and shaft in position.
2. Coat countershaft thrust washer with grease and place into case and position cluster gear assembly in bottom of case.
3. Install output shaft assembly into case through cover opening and place first gear thrust washer on roll pin and holding it securely. Install rear bearing, with snap ring groove facing rearward followed by the snap ring.
4. Install input shaft and fourth gear blocker ring through front of case, engaging notches in blocker ring with inserts on synchronizer.
5. Install front bearing gasket and retainer and torque bolts to 11-15 ft lbs (14-20 Nm). Apply a suitable sealer to bolt threads.
6. Align countershaft gear bore and thrust washers with case bore and install countershaft through rear of case.
7. Install reverse idle gear lever assembly with fork positioned in reverse idler gear groove. Apply a suitable sealer to threads of reverse lever pivot bolt and install bolt into case. Align lever on pivot bolt, torque bolt to 15-25 ft lbs (20-33 Nm), and install reverse lever spring clip.
8. Install cover gasket and cover, wiring clips and torque bolts to 7-10 ft lbs (9-13 Nm). The two (shouldered) locating bolts must be installed first and place shift rail into first or third gear position.
9. Install speedometer drive gear lock ball into hole and holding the ball, slide speedometer drive gear into place and secure with a snap ring. On some models, the speedometer drive gear is secured with a clip.
10. Install extension housing gasket and extension housing onto case and with a suitable sealer applied to the threads of attaching bolts, torque bolts to 18-27 ft lbs (24-36 Nm).
11. Install offset lever onto shifter shaft and torque nut to 14-20 ft lbs (19-27 Nm).
12. Install gearshift lever and check gear positions for proper operation.
13. Drive new access plug into rear of extension housing.