Disassembly

Ford M5R2 Five Speed Transmission (Part 1 Of 3):

Ford M5R2 Five Speed Transmission (Part 2 Of 3):

Ford M5R2 Five Speed Transmission (Part 3 Of 3):

1. Remove transmission drain plug and drain fluid.
2. Remove four shift control housing bolts, then pry up gently on the housing.
3. Remove offset lever retaining pin located in the extension housing using a punch and hammer. If necessary to remove rear seal from extension housing, extension housing must remain installed to transmission case. Remove extension housing rear seal using extension housing seal remover tool No. T74P-77248-A or equivalent.
4. Remove extension housing bolts, then extension housing from the case.
5. Remove countershaft oil funnel. Note position of tabs for assembly.
6. Remove top cover retaining bolts, then the top cover.
7. Remove shift rail and selector finger assembly from transmission case.
8. Remove offset lever and control selector spring from extension housing.
9. If necessary, remove gearshift lever guide.
10. If necessary, remove fifth-reverse inhibitor assembly.
11. If necessary, remove shift rail bushings.
12. If necessary, remove rear oil trough from extension housing.
13. Remove and discard anti-spill oil seal from output shaft.
14. Remove speedometer snap ring, drive gear and steel ball.
15. Lock transmission into first and third gears, then using countershaft locknut 2staking tool No. T77J-7025-F or equivalent, release the staked areas securing output shaft and countershaft locknuts, staked areas of locknuts must be fully released or damage to shaft threads will result.
16. Using mainshaft locknut wrench T88T-7025-A and remover tube T85T-7025-A or equivalent, remove and discard output shaft locknut.
17. Remove and discard the countershaft rear bearing and thrust washer.
18. Remove the reverse idler shaft fixing bolt and washer, then gear assembly by pulling rearward.
19. Remove output shaft rear bearing from output shaft using remover/replacer tube tool No. T85T-7025-A, TOD forcing screw tool No. T84T-7025-B, bearing puller tool No. T77J-7025-H and puller ring tool No. T77J-7025-J or equivalent.
20. Remove reverse gear, sleeve, counter reverse gear with two needle bearings and the reverse synchronizer ring.
21. Remove thrust washer and split washer from countershaft.
22. Remove fifth-reverse shift rod fixing bolt, counter lever assembly fixing bolt and inner circlip.
23. Remove counter lever assembly from transmission case. Do not remove Torx nut retaining the counter lever pin at this time.
24. Remove fifth-reverse synchronizer hub and sleeve assembly (countershaft).
25. Remove fifth-reverse shift fork and rail.
26. Remove fifth gear, fifth gear bearing assembly (two piece) and fiber-lined blocker ring. Do not separate steel ball and spring from shift fork groove unless necessary.
27. Remove fifth gear sleeve, ball and fifth gear from output shaft Note for reference during assembly that the longer of the two collars on fifth gear faces forward.
28. Remove center cover bolts, then the center cover. The arrow in the center of the bearing cover is to point upward during assembly.
29. Remove front bearing cover retaining bolts then the front bearing cover by threading two retaining bolts into opposite service bolt locations. Bolts threaded into service locations will bottom out and lift cover off. Do not remove plastic scoop ring from input shaft at this time. Remove plastic scoop only if input shaft bearing is to be replaced. Plastic scoop cannot be reused.
30. If necessary, press out front cover seal using a 30 mm hex deep well socket and an arbor press.
31. Remove oil trough retaining bolt and oil trough from support transmission case.
32. Pull input shaft forward and remove input shaft bearing outer race.
33. Remove countershaft bearing outer races by moving countershaft forward and rearward.
34. Pull countershaft rearward far enough to permit tool clearance behind front countershaft bearing. If necessary, remove front countershaft bearing using bearing race puller tool No. T88T-7120-A and slide hammer tool No. T50T-100-A or equivalent. Tap gently during bearing removal, as damage can occur to bearing or transmission case.
35. Pull input shaft forward with flats facing top and bottom and separate it from output shaft assembly. Tilt output shaft upward and lift it from transmission case.
36. Remove input shaft and fourth gear blocker ring, then lift countershaft through upper opening of transmission case.