Disassembly And Assembly Of Subassemblies: Case: Disassembly

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Using the special tools, remove the countershaft bearing cup and shim. Discard the shim.
- Inspect the countershaft bearing cup for wear or damage. Install a new cup as necessary.
- Install a new cup if the countershaft front bearing was installed new.
  
  Fig 1: Removing Countershaft Bearing Cup And Shim
  Courtesy of FORD MOTOR CO.

NOTE: Oil pump removal is only necessary if a large amount of particles were in the transmission during disassembly.

Fig 2: Removing Oil Pump Snap Ring

Courtesy of FORD MOTOR CO.

Remove the oil pump snap ring.
Remove the oil pump assembly.
- Using vise-grips, pull upward on the center shaft.
- Thoroughly clean the oil pump housing. Inspect the oil pump for wear or damage. Install a new oil pump assembly as necessary.
  
  Fig 3: Pulling Upward On Center Shaft
  Courtesy of FORD MOTOR CO.
Using a brass drift, dent the input shaft oil baffle for puller tool clearance.

Fig 4: Using A Brass Drift To Dent Input Shaft Oil Baffle For Puller Tool Clearance
Courtesy of FORD MOTOR CO.
Using the special tools, remove the input shaft bearing cup.
- Inspect the input shaft bearing cup for wear or damage. Install a new cup as necessary.
- Install a new cup if the input shaft bearing was installed new.
  
  Fig 5: Removing Input Shaft Bearing Cup
  Courtesy of FORD MOTOR CO.
Remove the input shaft oil dam bearing ring.

Fig 6: Removing Input Shaft Oil Dam Bearing Ring
Courtesy of FORD MOTOR CO.
Remove the input shaft shim. Discard the shim.

Fig 7: Removing Input Shaft Shim
Courtesy of FORD MOTOR CO.
Remove the oil trough.

Fig 8: Removing Oil Trough
Courtesy of FORD MOTOR CO.
Remove the guide tube.

Fig 9: Removing Guide Tube
Courtesy of FORD MOTOR CO.
Remove the input shaft oil seal.

Fig 10: Removing Input Shaft Oil Seal
Courtesy of FORD MOTOR CO.
Remove the PTO cover.

Fig 11: Removing PTO Cover
Courtesy of FORD MOTOR CO.

NOTE: Inspect the bearing for wear or damage before removing.

Fig 12: Removing Shift Rail Bearing

Courtesy of FORD MOTOR CO.

Using the special tools, remove and discard the shift rail bearing.