Assembly

Special Tools:

1. Using a press, install front countershaft bearing onto countershaft cluster gear using Pinion Bearing Cone Replacer T57L-4621-B.
2. Position countershaft cluster gear in case.





3. CAUTION: Failure to properly support the countershaft cluster gear can result in permanent distortion of the case during bearing installation.

NOTE: Support the countershaft cluster gear using two pieces of 7 mm (1/4-inch) bar stock.

Using a press, Cluster Gear Bearing Replacer T83P-7025-AH and Remover Tube T77J-7025-B, install countershaft rear bearing to countershaft cluster gear.





4. Install rear countershaft bearing cup onto countershaft cluster gear.





5. NOTE: This step should be done initially without any shims installed.

Install countershaft rear bearing retainer to transmission case Tighten bolts to 15-27 Nm (111-19 ft. lbs.).





6. Measure end play using Dial Indicator with Bracketry TOOL-4201-C or equivalent.

Remove countershaft rear bearing retainer and install necessary shim(s) between countershaft rear bearing retainer and rear countershaft bearing cup. Verify end play is within 0.0254-0.127 mm (0.001-0.005 inch). After installing countershaft rear bearing retainer, bend tabs on countershaft rear bearing retainer over the four retaining bolts.





7. Position reverse idler gear and bushing in case with shift lever groove facing rear of case.

Install reverse idler gear shaft and reverse gear overtravel stop. Install reverse idler gear shaft from rear of case and position reverse gear overtravel stop between reverse idler gear and bushing and reverse idler gear shaft.





8. Using a 5 mm (3/16-inch) pin punch, install reverse idler gear shaft roll pin.
9. If removed, apply Pipe Sealant with Teflon D8AZ-19554-A or equivalent meeting Ford specifications WSK-M2G350-A2 and ESR-M18P7-A to shift rail rear pin threads. Install anchor pin and tighten to 8-15 Nm (71-132 inch lbs.).





10. Align reverse gearshift lever, reverse shift fork and reverse positioning spring as shown.





11. Lower assembly into case and install looped end of reverse positioning spring onto anchor pin.





12. NOTE: Observe reverse positioning spring rotation. Reverse positioning spring should rotate counterclockwise into its installed position.

Position reverse idler gear and bushing into the NEUTRAL position and align reverse shift fork onto reverse idler gear and bushing. Once aligned, push downward on reverse shift fork until fully engaged into reverse idler gear and bushing.





13. Install output and fifth gear drive shaft as an assembly.





14. Coat the 15 bearings and spacer or sleeve and snap ring with Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-A and ESR-M1C159-A. Install components in input shaft.





15. Align notches in synchronizer blocking ring with synchronizer hub inserts in three/four synchronizer and install synchronizer blocking ring.





16. NOTE: Make sure three/four synchronizer blocking ring is still in proper position.

Install input shaft. Align flat on synchronizer teeth with countershaft cluster gear before installing input shaft.





17. Install output shaft rear bearing cup in main drive gear bearing retainer.

18. NOTE: Do not install end play shims at this point.

Temporarily, install main drive gear bearing retainer with narrow or smaller notch facing upward. Do not apply sealant to the main drive gear bearing retainer at this point.





19. Tighten retaining bolts to 15-27 Nm (11-19 ft. lbs.).





20. Install output shaft rear bearing cup. If necessary, tap output shaft rear bearing cup into position using a plastic-tipped hammer.





21. Install reverse gear shift rail into transmission case by aligning ball stud with slot in case and aligning reverse gear shift rail with reverse shift fork. Once ball stud enters case, rotate reverse gear shift rail clockwise and push in reverse gear shift rail until ball aligns with reverse gearshift lever. Rotate reverse gear shift rail counterclockwise until ball stud fully engages reverse gearshift lever.





22. Install fifth speed cluster gear, synchronizer and gear shifter fork as an assembly.





23. NOTE: Alignment tab on the brake ring must engage the alignment slot in the extension housing when installing the extension housing to prevent component damage.

Install synchronizer blocking ring , brake ring, retainer and fifth gear synchronizer snap ring.





24. NOTE: Before installing the shift rail rear pin, make sure the reverse gear shift rail ball stud is fully engaged with the reverse gearshift lever.

Apply Pipe Sealant with Teflon D8AZ-19554-A or equivalent meeting Ford specifications WSK-M2G350-A2 and ESR-M18P7-A to the shift rail rear pin threads and install the shift rail rear pin.

Tighten shift rail rear pin to 34-47 Nm (25-34 ft. lbs.) using a T55 Torx driver. Apply Pipe Sealant with Teflon D8AZ-19554-A or equivalent meeting Ford specifications WSK-M2G350-A2 and ESR-M18P7-A to the backup lamp switch and install using a 22 mm socket. Tighten to 27-47 Nm (20-34 ft. lbs.).





25. Using needle nose pliers, install reverse idler gear retaining ring on shift rail rear pin.





26. NOTE: The tab on the speedometer drive gear retaining clip engages a hole in the output and fifth gear drive shaft.

Install speedometer drive gear.

27. CAUTION: Do not apply silicone sealer to top of transmission case surface under any circumstances, as sealant could fall into transmission and affect operation.

Apply 3.2 mm (1/8 inch) bead of Silicone Rubber (clear) D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A to case cover assembly.





28. NOTE: Make sure all synchronizers are in the NEUTRAL position and that the gear shifter forks in the case cover are in the NEUTRAL position.

Position case cover to filler plug side of transmission and lower into position until gear shifter forks engage synchronizers. Continue lowering case cover and move into position to engage reverse gearshift lever. Install case cover retaining bolts. Tighten case cover retaining bolts to 8-15 Nm (71-132 inch lbs.).





29. NOTE: Alignment tab on brake ring must engage alignment slot in extension housing when installing extension housing to prevent component damage.

Apply a 3.2 mm (1/8-inch) bead of Silicone Rubber (clear) D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A on the extension housing mating surface. Apply silicone rubber to the oil pick-up funnel and install funnel to extension housing.





30. Coat shifter interlock spring with petroleum jelly and install in gearshift offset lever. Lubricate detent plate and install detent ball in neutral position on plate. Position gearshift offset lever in extension housing with shifter interlock spring over detent ball.





31. NOTE: Make sure lubrication funnel engages into fifth-gear synchronizer.

Slide gearshift offset lever and extension housing into position as an assembly.





32. Press downward on gearshift offset lever to compress shifter interlock spring and push gearshift offset lever and extension housing into position.





33. Install extension housing retaining bolts. Tighten to 47-61 Nm (35-44 ft. lbs.).





34. Using a suitable pin punch, align the hole in main shift control shaft with hole in gearshift offset lever and install roll pin.

Install gearshift shaft bushing in gearshift offset lever.





35. NOTE: Output shaft gear train end play must be checked and adjusted at this point.

Check output shaft gear train end play as follows:
^ Rotate transmission to the vertical position with extension housing facing up.
^ Mount Dial Indicator with Bracketry TOOL-4201-C or equivalent on the extension housing with the indicator stylus contacting the output and fifth gear drive shaft.
^ Rotate the input shaft and output and fifth gear drive shafts. Zero the dial indicator.





^ Using a wood block, push upward on the input shaft and note the dial indicator reading.





36. CAUTION: Thickest shim must be installed closest to the front bearing cup for necessary cup support.

CAUTION: Although zero end play is the ideal end play up to 0.050 mm (0.002 inch) is an acceptable tolerance. Do not overload the bearings with too thick a shim as transmission damage may occur.

NOTE: A shim must be installed that is the thickness of the dial indicator reading. This will provide zero end play.

Rotate transmission to the horizontal position and remove the main drive gear bearing retainer. Remove bearing race from main drive gear bearing retainer and install the necessary shim(s).

Shim Thickness In Thousandths Of An Inch:

37. CAUTION: The sealer must not cover the notch in the main drive gear bearing retainer

Apply a 3.2 mm (1/8 inch) bead of Silicone Rubber (clear) D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A to main drive gear bearing retainer.

Install main drive gear bearing retainer with narrow or smaller notch facing upward and tighten retaining bolts to 15-27 Nm (11-19 ft. lbs.). Check end play.





38. Apply a 3.2 mm (1/8 inch) bead of Silicone Rubber (clear) D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A on the shift housing cover.





39. Position gearshift lever on the extension housing and tighten the retaining bolts to 17-20 Nm (13-14 ft. lbs.).





40. Install a new oil-seal using Extension Housing Seal Replacer T94P-7657-A.





41. Install and tighten case plug to 17-29 Nm (13-21 ft. lbs.).
42. Install transmission.