Assembly

Special Tools:

1. Soak the blocking rings in transmission fluid for ten minutes.
^ Use MERCON(R) Multi-Purpose ATF Transmission Fluid XT-2-QDX or equivalent.





2. Attach the case to the special tool.





3. Lubricate the bearing cups and the main shift rail bushing with petroleum jelly.





4. Install the main shift rail assembly onto the output shaft.

5. CAUTION: To prevent component damage, do not lift the output shaft assembly by lifting up on the third/fourth synchronizer assembly.





Position the assembly in the case.

6. Note: If not done so previously, soak the blocking ring in MERCON(R) Multi-Purpose ATF Transmission Fluid XT-2-QDX or equivalent for ten minutes.





Install the fourth speed blocking ring.
^ Align the pockets in the blocking ring with the struts in the synchronizer assembly.

7. CAUTION: To prevent component damage, do not raise the output shaft assembly by lifting up on the third/fourth synchronizer assembly.





Push the output shaft assembly upward approximately 25 mm (1 inch) and install the countershaft cluster gear.





8. Apply sealant to the interlock bolt threads and install the bolt.
^ Use Pipe Sealant with Teflon D8AZ-19544-A or equivalent meeting Ford specification ESR-M18P7-A.





9. Install the fifth/reverse lever pivot bolt and the fifth/reverse gear shift lever.
^ Install a new pivot bolt or apply Pipe Sealant with TeflontI9 D8AZ- 19554-A or equivalent meeting Ford specification ESR-M18P7-A to the existing bolt threads.





10. Install the fifth/reverse lever retaining clip.





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





12. Install the input shaft.
^ Lubricate the input shaft front bearing and the input shaft pocket bearing with petroleum jelly.





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





14. Install four opposing bolts.
^ Verify that the input shaft turns freely.





15. Using the special tool, measure the input shaft end play by applying an upward load on the output shaft.
^ If the end play is not within the specification, install a different thickness shim behind the input shaft front bearing assembly cup.
16. Turn the case so that the input shaft is facing downward.
^ Verify that the countershaft cluster gear turns freely.





17. Using the special tool, measure the countershaft cluster gear end play by applying an upward load on the countershaft cluster gear.
^ If the end play is not within the specification, install a different thickness shim behind the front countershaft bearing assembly cup.





18. Apply a 3.2-mm (1/8-inch) bead of silicone rubber to the sealing surface on the flywheel housing and install the flywheel housing. Tighten the bolts in a star pattern.
- Use Clear Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A.





19. Attach the special tool to the flywheel housing. Position the transmission so that the input shaft is facing downward.





20. Install the fifth gear with the synchronizer cone facing the rear of the countershaft cluster gear.

21. Note: If not done so previously, soak the blocking ring in MERCON(R) Multi-Purpose ATF Transmission Fluid XT-2-QDX or equivalent for ten minutes.





Install the fifth speed blocking ring.
22. Position the fifth/reverse synchronizer sleeve and the reverse synchronizer sleeve into the fifth/reverse gear shifter fork.

23. Note: Align the fifth/reverse synchronizer struts with the X on the synchronizer sleeve.





Simultaneously slide the reverse synchronizer sleeve, the fifth/reverse gear shifter fork, and the fifth/reverse synchronizer sleeves onto the fifth/reverse gear shift rail, the output shaft, and the countershaft.

24. Note:
^ The fifth/reverse synchronizer hub is reversible.
^ Verify that the synchronizer struts are indexed with the pockets in the fifth speed blocking ring.





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





25. Install the reverse synchronizer hub with the hub splines facing the rear of the output shaft.





26. Align the fifth/reverse gear shifter fork and install the split pin.





27. Install the retaining ring with the gap end bevel facing downward.

28. Note: If not done so previously, soak the blocking ring in MERCON Multi-Purpose ATF Transmission Fluid XT-2-QDX or equivalent for ten minutes.





Install the reverse speed blocking ring.
^ Align the pockets in the blocking ring with the struts in the synchronizer.





29. Install the reverse gear.





30. Install the thrust washer.





31. Install the retaining ring with the gap bevel facing downward.





32. Install the retaining ring.





33. Install the bearing spacer.





34. lubricate the needle bearing with petroleum jelly and install the bearing.





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





36. Install the thrust washer.





37. Install the retaining ring with the gap bevel facing downward.





38. Measure the clearance between the reverse driven gear and the reverse synchronizer hub.
^ Pull the reverse driven gear toward the rear of the shaft until it bottoms on the spacer and retaining ring.
^ If the clearance is not within the specification, install a new bearing spacer.





39. Using the special tools, install the output shaft rear bearing.





40. Install the retaining ring with the gap bevel facing downward.





41. Install the retaining ring with the gap bevel facing downward.





42. Install the tone wheel with the chamfer facing downward.





43. Install the retaining ring with the gap bevel facing downward.





44. Apply a 3.2-mm (1/8-inch) bead of silicone rubber to the sealing surface on the case.
^ Use Clear Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specifications ESB-M4G92-A.





45. Position the gearshift offset lever in the extension housing.
1. Coat the detent spring with petroleum jelly and install it into the gearshift offset lever.
2. Lubricate the detent plate and install the detent ball into the neutral position on the plate.
3. Position the gearshift offset lever in the extension housing with the detent spring over the detent ball.





46. Slide the gearshift offset lever and the extension housing into place as an assembly. Press downward on the gearshift offset lever to compress the detent spring and push the gearshift offset lever and extension housing into place.





47. Install the identification tag and the bolts.





48. Align the gearshift offset lever pin hole and the main shift rail pin hole and install the split pin.
49. Apply a 3.2-mm (1/8-inch) bead of silicone rubber to the sealing surface on the gearshift lever.
^ Use Clear Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specifications ESB-M4G92-A.





50. Align the shifter ball and the gearshift offset lever socket and install the gearshift lever.





51. Apply sealant to the case plug threads and install the plug.
^ Use Pipe Sealant with Teflon D8AZ-19554-A or equivalent meeting Ford specification ESR-M18P7-A.





52. Apply sealant to the reversing lamp switch threads and install the switch.
^ Use Pipe Sealant with Teflon(R) D8AZ-19554-A or equivalent meeting Ford specification ESR-M18P7-A.





53. Lubricate the full fill seal with petroleum jelly and install it with the chamfer facing forward. Position the seal approximately 25 mm (1 inch) from the rear of the output shaft.





54. Install the fill plug.
55. Install the clutch release hub and bearing and the clutch release lever.