Assembly

Special Tools:

1. Position the case in the special tool.





2. Using petroleum jelly, lubricate the bearing races and the main shift rail bushing.





3. Install the main shift rail assembly onto the mainshaft assembly.





4. Install the mainshaft/main shift rail assembly.





5. Install the fourth gear blocker ring.
^ Soak the blocker ring in Motorcraft MERCON(R) Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or equivalent for ten minutes.
^ Align the pockets in the blocker ring with the inserts in the synchronizer assembly.
^ Install the fourth gear blocker ring.





6. Note: Do not lift the mainshaft assembly by the third/fourth synchronizer assembly.

Lift the mainshaft assembly up approximately 25mm (1 inch) and install the countershaft cluster gear.





7. Install the bolt.
^ Apply Pipe Sealant with Teflon(R) D8AZ-19544-A or equivalent meeting Ford specifications WSK-M2G350-A2.





8. Install the reverse gearshift lever.
^ Use a new pivot pin bolt or apply Pipe Sealant with Teflon(R) DBAZ-19554-A or equivalent meeting Ford specifications WSK-M2G350-A2 on the existing pivot pin bolt.
^ Install the reverse gearshift lever.
^ Install the pivot pin bolt.





9. Install the reverse gearshift retaining clip.





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





11. Install the input shaft.
^ Using petroleum jelly, lubricate the input shaft support bearing and the input shaft pocket bearing.
^ Install the input shaft.





12. Install the flywheel housing.
^ Lubricate the bearing cups with petroleum jelly.
^ Align the shift rails and install the flywheel housing.





13. Install four opposing bolts.





14. Measure the input shaft endplay.
1 Make sure the input shaft turns freely.
2 Position the special tools.
3 Apply an upward load on the output shaft.
4 End play must be between 0.025 - 0.051 mm (0.0009 - 0.0020 inch).
5 If required, select a shim to correct the end play. Shim at the input shaft pocket bearing outer bearing cup.





15. Measure the countershaft cluster gear end play.
1 Make sure the countershaft cluster gear turns freely.
2 Position the special tools.
3 Apply an upward load on the countershaft cluster gear.
4 End play must be between 0.0 - 0.076mm (0.0 - 0.0030 inch).
5 If required, select a shim to correct the end play. Shim at the countershaft front bearing cup.





16. Install the flywheel housing.
^ Apply a 3.2 mm (1/8 inch) bead of Clear Silicone Rubber D6AZ- 19562-AA or equivalent meeting Ford specification ESB-M4G92-A to the mating surfaces.
^ Install the flywheel housing.
^ Install the bolts. Tighten the bolts in a star pattern.





17. Position the special tool on the flywheel housing and position the transmission with the output shaft facing up.





18. Install the fifth speed cluster gear with the synchronizer cone to the rear of the countershaft cluster gear.





19. Install the fifth speed blocker ring.
^ Soak the blocker ring in Motorcraft MARCON(R) Multi-Purpose (ATF) Transmission F1uid XT-2-QDX or equivalent for ten minutes.
^ Install the fifth speed blocker ring.





20. Note: The fifth/reverse synchronizer struts must align with the X on the synchronizer sleeve.

Install the fifth/reverse fork.
^ Position the fifth/reverse synchronizer sleeve and the reverse synchronizer sleeve into the fifth/reverse fork.
^ Simultaneously slide the fifth/reverse fork and the synchronizer sleeves onto the reverse shift rail, the mainshaft and the countershaft.





21. Note: The fifth/reverse synchronizer hub is reversible. Verify that the synchronizer struts are indexed with the pockets in the fifth gear blocking ring during installation.

Using the special tool, install the fifth/reverse synchronizer hub.





22. Install the reverse gear synchronizer hub with the hub splines facing toward the rear.





23. Align the fifth/reverse shift fork and install the split pin.





24. Install the retaining ring with the gap end bevel facing down.





25. Install the reverse synchronizer hub retaining ring.





26. Install the reverse driven gear bearing thrust washer.





27. Using petroleum jelly, lubricate and install the reverse gear mainshaft bearing.





28. Install the reverse countershaft blocker ring.
^ Soak the blocker ring in Motorcraft MERCON(R) Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or equivalent for ten minutes.
^ Align the pockets of the blocker ring with the inserts of the synchronizer hub.
^ Install the reverse drive gear blocker ring.





29. Install the reverse drive gear.





30. Install the reverse gear spacer.





31. Install the reverse drive gear retaining ring with the gap bevel facing down.





32. Install the reverse driven gear with the clutching teeth facing the synchronizer.





33. Install the reverse gear select spacer.





34. Install the reverse gear spacer retaining ring with the gap bevel facing down.





35. Measure the reverse speed gear clearance.
^ Pull the reverse speed gear toward the rear of the shaft until it bottoms on the spacer and retaining ring.
^ The clearance between the reverse speed gear and the reverse synchronizer hub must be 0.05 - 0.30 mm (0.002 - 0.012 inch).
^ If the clearance is not within specification, install a new spacer.





36. Using the special tools, install the output shaft support bearing.





37. Install the output shaft bearing retaining ring with the gap bevel facing down





38. Install the OSS tone wheel gear front retaining ring with the gap bevel facing down.





39. Install the OSS tone wheel gear with the chamfer facing down.
40. Install the rear OSS tone wheel gear retaining ring with the gap bevel facing down.





41. Apply a 3.2 mm (1 inch) bead of Clear Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specifications ESB-M4G92-A to the mating surfaces.





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





43. Slide the gearshift offset lever and the extension housing into place as an assembly.
44. Press downward on the gearshift offset lever to compress the shifter interlock spring and push the gearshift offset lever and extension housing into place.





45. Install the bolts.





46. Align the gearshift offset lever pin hole and the main shift rail pin hole and install the split pin.





47. Install the gearshift lever.
^ Apply a 3.2 mm (1 inch) bead of Clear Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specifications ESB-M4G92-A to the mating surfaces.
^ Align the shifter ball and the gearshift offset lever socket and install the gearshift lever.
^ Install the four bolts.





48. Apply Pipe Sealant with Teflon(R) D8AZ-19554-A or equivalent meeting Ford specification WSK-M2G350-A2 and to the case plug and install.





49. Apply pipe sealant to the backup lamp switch and install.





50. Lubricate the full fill seal with petroleum jelly and install it with the champher facing forward approximately 25 mm (1 inch) from the rear of the output shaft.
51. Fill the transmission with 3.1 - 3.3L (107 - 111 ounces) of Motorcraft MERCON(R) Multi-purpose (ATF) Transmission Fluid XT-2-QDX or equivalent.





52. Apply Pipe Sealant with Teflon(R) D8AZ-19554-A or equivalent meeting Ford specification WSK-M2G350-A2 to the fill hole plug and install.