Section 1033 (Manual Transmission -- F150 Pickup): Disassembly: Transmission

WARNING: This page is about a different car, the 2005 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.

SPECIAL TOOL CHART

	Remover, Mainshaft Bearing 308-058 (T77J-7025-H)
	Remover, Front Cover 308-171 (T88T-7025-D)
	Socket, Transmission Shaft Locknut 308-168 (T88T-7025-AR)
	Remover/Installer, Bearing Tube 308-024 (T75L-7025-B)
	Removal Screw, Bearing Tube 308-092 (T84T-7025-B)

WARNING: Wear protective eyewear whenever using compressed air.

Clean the transmission exterior with solvent and dry with compressed air.

WARNING: Wear protective eyewear whenever using compressed air.

Clean all parts removed with solvent and dry with compressed air.
Set the transmission on a work bench.
Remove the case cover.
1. Remove the 10 shift control housing bolts.
2. Separate the shift control housing from the transmission.
Fig 1: Removing Case Cover
Courtesy of FORD MOTOR CO.
Remove the shift control housing seal.

Fig 2: Removing Shift Control Housing Seal
Courtesy of FORD MOTOR CO.
Remove the extension housing.
1. Remove the 9 extension housing bolts.
2. Separate the extension housing from the transmission.
Fig 3: Removing Extension Housing
Courtesy of FORD MOTOR CO.
Remove the shipping seal.

Fig 4: Removing Shipping Seal
Courtesy of FORD MOTOR CO.
Remove the tone ring retaining ring and the vehicle speed sensor (VSS) tone ring.

Fig 5: Removing Tone Ring Retaining Ring
Courtesy of FORD MOTOR CO.
Remove the locating ball.

Fig 6: Removing Locating Ball
Courtesy of FORD MOTOR CO.
Slide the lst/2nd and 3rd/4th synchronizer sleeves forward to lock the transmission into 1st and 3rd gears.

Fig 7: Sliding 1st/2nd And 3rd/4th Synchronizer Sleeves Forward To Lock Transmission
Courtesy of FORD MOTOR CO.

NOTE: Release the stake mark on the nut.

Fig 8: Removing Countershaft Locknut

Courtesy of FORD MOTOR CO.

Remove and discard the countershaft locknut.
Remove the countershaft rear bearing and the countershaft rear bearing thrust washer.

Fig 9: Removing Countershaft Rear Bearing And Countershaft Rear Bearing Thrust Washer
Courtesy of FORD MOTOR CO.

NOTE: Release the stake mark on the nut.

Fig 10: Removing Output Shaft Rear Bearing Locknut Using Special Tool

Courtesy of FORD MOTOR CO.

Using the special tool, remove the output shaft rear bearing locknut.
Remove the reverse idler shaft bolt.

Fig 11: Removing Reverse Idler Shaft Bolt
Courtesy of FORD MOTOR CO.
Remove the reverse idler gear.

Fig 12: Removing Reverse Idler Gear
Courtesy of FORD MOTOR CO.
Using the special tools, remove the output shaft bearing.

Fig 13: Removing Output Shaft Bearing Using Special Tools
Courtesy of FORD MOTOR CO.
Remove the output shaft reverse gear and bushing.

Fig 14: Removing Output Shaft Reverse Gear And Bushing
Courtesy of FORD MOTOR CO.
Remove the output shaft spacer.

Fig 15: Removing Output Shaft Spacer
Courtesy of FORD MOTOR CO.
Remove the following components:
- Countershaft reverse gear
- Two countershaft reverse gear bearings
- Reverse synchronizer blocking ring
- Reverse gear thrust washer
Fig 16: Removing Countershaft Reverse Gear, Countershaft Reverse Gear Bearings, Synchronizer Blocking Ring And Gear Thrust Washer
Courtesy of FORD MOTOR CO.
Remove the countershaft split washer.

Fig 17: Removing Countershaft Split Washer
Courtesy of FORD MOTOR CO.
Remove the reverse gear shift rail bolt.

Fig 18: Removing Reverse Gear Shift Rail Bolt
Courtesy of FORD MOTOR CO.
Remove the 5th/reverse synchronizer, the gear shifter fork and the reverse gear shift rail as an assembly.

Fig 19: Removing 5th/Reverse Synchronizer, Gear Shifter Fork And Reverse Gear Shift Rail As An Assembly
Courtesy of FORD MOTOR CO.
Separate the gear shifter fork from the 5th/reverse synchronizer.

Fig 20: Separating Gear Shifter Fork From 5th/Reverse Synchronizer
Courtesy of FORD MOTOR CO.
Remove the countershaft 5th gear synchronizer blocking ring and 5th gear.

Fig 21: Removing Countershaft 5th Gear Synchronizer Blocking Ring And 5th Gear
Courtesy of FORD MOTOR CO.
Remove the following components:
- Countershaft 5th gear split bearing
- Inner race
- Locating ball
Fig 22: Removing Countershaft 5th Gear Split Bearing
Courtesy of FORD MOTOR CO.
Remove the 5th/reverse shift lever retaining ring, the washer and the 5th/reverse shift lever.

Fig 23: Removing 5th/Reverse Shift Lever Retaining Ring, Washer And 5th/Reverse Shift Lever
Courtesy of FORD MOTOR CO.
Remove the lock plate bolt, then slide the shaft out of the case.

Fig 24: Removing Lock Plate Bolt
Courtesy of FORD MOTOR CO.
Remove the output shaft 5th speed gear.

Fig 25: Removing Output Shaft 5th Speed Gear
Courtesy of FORD MOTOR CO.
Remove the 2 clutch slave cylinder bolts and the clutch slave cylinder.

Fig 26: Removing Clutch Slave Cylinder Bolts And Clutch Slave Cylinder
Courtesy of FORD MOTOR CO.
Remove the rear bearing retainer bolts and the rear bearing retainer, then remove the rear countershaft bearing.

Fig 27: Removing Rear Bearing Retainer Bolts, Rear Bearing Retainer And Rear Countershaft Bearing
Courtesy of FORD MOTOR CO.
Remove the 6 front bearing retainer bolts.
- Install the special tool into the slave cylinder bolt locations. Remove the front bearing retainer.
- Alternately tighten the bolts until the front bearing retainer can be removed by hand.
- Remove the front bearing retainer.
Fig 28: Removing Front Bearing Retainer Bolts
Courtesy of FORD MOTOR CO.
Remove the fluid baffle shim.

Fig 29: Removing Fluid Baffle Shim
Courtesy of FORD MOTOR CO.
Remove the front bearing retainer seal.
- Discard the seal.
Fig 30: Removing Front Bearing Retainer Seal
Courtesy of FORD MOTOR CO.
Remove the fluid baffle.

Fig 31: Removing Fluid Baffle
Courtesy of FORD MOTOR CO.
Remove the front countershaft bearing.

Fig 32: Removing Front Countershaft Bearing
Courtesy of FORD MOTOR CO.
Remove the fluid passage bolt.

Fig 33: Removing Fluid Passage Bolt
Courtesy of FORD MOTOR CO.
Remove the fluid passage.

Fig 34: Removing Fluid Passage
Courtesy of FORD MOTOR CO.
Remove the input shaft front bearing race.

Fig 35: Removing Input Shaft Front Bearing Race
Courtesy of FORD MOTOR CO.
Remove the output shaft center bearing race and the center countershaft bearing.

Fig 36: Removing Output Shaft Center Bearing Race And Center Countershaft Bearing
Courtesy of FORD MOTOR CO.
Separate the input shaft from the output shaft.
- Move the countershaft rearward and rotate the input shaft to position the flat section downward.
Fig 37: Moving Countershaft Rearward
Courtesy of FORD MOTOR CO.
Remove the output shaft.
- Move the countershaft down to gain room then remove the output shaft.
Fig 38: Removing Output Shaft
Courtesy of FORD MOTOR CO.
Remove the input shaft.

Fig 39: Removing Input Shaft
Courtesy of FORD MOTOR CO.
Remove the countershaft.

Fig 40: Removing Countershaft
Courtesy of FORD MOTOR CO.