Section 671 (Manual Transmission - F250-F550 Super Duty): Disassembly: Transmission

Special Tool(s) 

Fig 1: Identifying Special Tool

Courtesy of FORD MOTOR CO.

Material 

All vehicles 

WARNING: Wear protective eyewear whenever using compressed air.
1. Clean the transmission exterior with solvent, and dry with compressed air.
WARNING: Wear protective eyewear whenever using compressed air.
2. Clean all parts removed with solvent, and dry with compressed air.
3. Remove the clutch release lever and the clutch release hub and bearing.
   Fig 2: Removing Clutch Release Lever

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NOTE: For vehicles equipped with gasoline engines, the transmission must be elevated, 50-101 mm (2-4 inches), to prevent damage to the input shaft.
Fig 3: Identifying Position Transmission On Floor With Output Flange Pointing Upward
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4. Position the transmission on the floor with the output flange pointing upward.

   4x2 vehicles 

5. Using the special tools, remove the pinion flange.
   Fig 4: Removing Pinion Flange

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   All vehicles 

6. Remove the 19 bolts.
   Fig 5: Removing Bolts

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NOTE: Use a 1/8 inch center punch to create a pilot hole in the plug before installing the tool. Using the Jet Plug Remover to make the pilot hole will damage the tool.
7. Using the special tool, remove the detent plugs and shift detent springs. Discard the detent plugs.
   • Lightly thread in the Jet Plug Remover so as not to damage the springs.
     Fig 6: Removing Detent Plugs

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8. Remove the main shift detent.
   Fig 7: Removing Main Shift Detent

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9. Separate the main shift detent from the detent plunger.
   • Inspect the detent plunger for wear or damage. Install a new dent plunger as necessary.
     Fig 8: Installing Dent Plunger

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10. Remove the extension housing from the intermediate housing.
    • Using a soft-faced hammer, tap the extension housing lightly to break the gasket seal.
      Fig 9: Removing Extension Housing From Intermediate Housing

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11. Remove the intermediate housing to case bolts.
    • Early production vehicles will have three bolts.
      Fig 10: Removing Intermediate Housing To Case Bolts (1 Of 2)

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      Fig 11: Removing Intermediate Housing To Case Bolts (2 Of 2)

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12. Using a suitable lifting device, a suitable chain and two S-hooks, lift the intermediate housing and gear assembly out of the main case.
    • Place the S-hooks in the intermediate housing where the two bolts were removed.
    • Place a protective cover or rag around the chain. This will ensure the low and reverse gears are not damaged during removal.
    • Lift the transmission 1 inch (25 mm) off the ground. Using a soft faced hammer, lightly tap the main housing to break the gasket seal.
      Fig 12: Lifting Intermediate Housing And Gear Assembly Out Of Main Case (1 Of 2)

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      Fig 13: Lifting Intermediate Housing And Gear Assembly Out Of Main Case (2 Of 2)

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13. Position the intermediate housing and gear assembly on the special tool.
    • Securely fasten the holding plate to a sturdy work bench.
      Fig 14: Identifying Position Intermediate Housing And Gear Assembly

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14. Remove the low/reverse/fifth gear main shift rail driver.
    1. Remove the two roll pins.
       • Use a hammer and punch or an air hammer and roll pin remover.
    2. Remove the main shift rail driver.
       Fig 15: Removing Main Shift Rail Driver

       Courtesy of FORD MOTOR CO.
NOTE: The shift finger is also the first/second and third/fourth rail driver.
15. Remove the lower roll pins.
    • Use a hammer and punch or an air hammer and roll pin remover to remove.
    • For vehicles equipped with a diesel engine, the shift finger is short. For vehicles equipped with a gas engine, the shift finger is long.
      Fig 16: Removing Lower Roll Pins (1 Of 2)

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      Fig 17: Removing Lower Roll Pins (2 Of 2)

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16. Remove the lower shift finger and the main shift rail.
    1. Remove the lower shift finger.
       • Rotate the rail driver counterclockwise and pull outward to remove.
    2. Remove the main shift rail.
       Fig 18: Removing Main Shift Rail

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17. Align the interlock plate into second gear position, engage second gear, then remove the two fifth gear shift fork roll pins.
    • Use a hammer and punch or an air hammer and roll pin remover to remove.
      Fig 19: Aligning Interlock Plate Into Second Gear Position

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18. Remove the fifth gear shift fork and shift rail.
    • Align the interlock plate into the fifth gear position. Remove the shift rail by tapping the shift fork with a soft faced hammer while pulling up on the shift rail.
      Fig 20: Removing Fifth Gear Shift Fork And Shift Rail

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19. Remove the low and reverse gear shift fork roll pin.
    • Use a hammer and punch or an air hammer and roll pin remover to remove.
      Fig 21: Removing Low And Reverse Gear Shift Fork Roll Pin

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20. Remove the low/reverse gear shift fork and shift rail.
    • Align the interlock plate into the low/reverse gear position. Remove the shift rail by tapping the shift fork with a soft faced hammer while pulling up on the shift rail and fork.
      Fig 22: Removing Low/Reverse Gear Shift Fork And Shift Rail

      Courtesy of FORD MOTOR CO.
21. Remove the shift rail detents, if necessary.
    • The shift rail detents can be difficult to remove. Using a heat gun, apply heat to the intermediate plate to ease removal.
      Fig 23: Removing Shift Rail Detents

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22. On 4-wheel drive vehicles, remove and discard the snap ring.
    Fig 24: Removing Snap Ring

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23. Using the special tools, remove the mainshaft rear bearing, the output bearing thrust washer, mainshaft low gear, the mainshaft low gear bushing, the synchronizer assembly (low and reverse) and the mainshaft reverse gear.
    Fig 25: Removing Mainshaft Rear Bearing

    Courtesy of FORD MOTOR CO.
24. Remove the mainshaft rear bearing and the output bearing thrust washer from the low and reverse assembly.
    • Inspect the bearing for wear or damage. Install a new bearing as necessary.
    • Always install new bearings and cups as a set. Do not install one without the other.
      Fig 26: Removing Mainshaft Rear Bearing

      Courtesy of FORD MOTOR CO.
25. Remove the mainshaft needle bearings.
    • Inspect the bearings for wear or damage. Install new bearings as necessary.
      Fig 27: Removing Mainshaft Needle Bearings

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26. Remove the low gear from the low and reverse synchronizer assembly.
    • Inspect the low and reverse gears for wear or damage. Install new gears as necessary.
      Fig 28: Removing Low Gear From Low And Reverse Synchronizer Assembly

      Courtesy of FORD MOTOR CO.
27. Disassemble the low and reverse synchronizer assembly.
    • Inspect the components for wear or damage. Inspect the internal surface of the synchronizer rings for a contact pattern. The contact pattern should be the same on the entire internal circumference of the ring.
      Fig 29: Disassembling Low And Reverse Synchronizer Assembly

      Courtesy of FORD MOTOR CO.
28. Check the clearance between the synchronizer ring and the gear.
    1. Place the synchronizer ring onto the synchronizer sliding sleeve. Position the synchronizer ring on the gear.
    2. Insert a feeler gauge and measure the clearance, while applying pressure and rotating the synchronizer ring. The clearance should be the same around the entire circumference.
       • Place the feeler gauge between the ring and gear. The ring has a raised section, inserting the feeler gauge past the teeth will give a incorrect reading.
       • If the clearance is less than 1.0 mm (0.04 in.) for low or reverse gear, install a new synchronizer assembly, low gear or reverse gear to obtain correct specification.
         Fig 30: Checking Clearance Between Synchronizer Ring And Gear

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29. Remove the mainshaft needle bearing.
    Fig 31: Removing Mainshaft Needle Bearing

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30. For vehicles equipped with a 6.0L engine, remove the low gear thrust washer.
    Fig 32: Removing Low Gear Thrust Washer

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31. Remove and discard the snap ring.
    Fig 33: Removing Snap Ring

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32. Remove the countershaft rear thrust washer.
    Fig 34: Removing Countershaft Rear Thrust Washer

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33. Remove fifth gear.
    Fig 35: Removing Fifth Gear

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34. Remove the countershaft needle bearing.
    Fig 36: Removing Countershaft Needle Bearing

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35. Remove the interlock plate bolts.
    Fig 37: Removing Interlock Plate Bolts

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NOTE: Do not use power tools to remove.
NOTE: Make sure the shift rails are not binding while pulling up on the intermediate housing.
36. Using the special tools, remove the countershaft bushing, the countershaft fifth gear synchronizer assembly and the intermediate housing.
    • When installing the Centerplate Legs, position them opposing one another.
    • Inspect the countershaft fifth gear synchronizer, countershaft bushing and the intermediate plate for wear or damage. Install new components as necessary.
      Fig 38: Removing Countershaft Bushing

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37. Disassemble the countershaft fifth gear synchronizer assembly.
    • Inspect the components for wear or damage. Inspect the internal surface of the synchronizer ring for a contact pattern. The contact pattern should be the same on the entire internal circumference of the ring.
      Fig 39: Disassembling Countershaft Fifth Gear Synchronizer Assembly

      Courtesy of FORD MOTOR CO.
38. Check the clearance between the synchronizer ring and the gear.
    1. Place the synchronizer ring onto the synchronizer sliding sleeve. Position the synchronizer ring on the gear.
    2. Insert a feeler gauge and measure the clearance, while applying pressure and rotating the synchronizer ring. The clearance should be the same around the entire circumference.
       • Place the feeler gauge between the ring and gear. The ring has a raised section. Inserting the feeler gauge past the teeth will give an incorrect reading.
       • If the clearance is less than 1.0 mm (0.04 in.) for fifth gear, install a new synchronizer assembly or fifth gear to obtain correct specification.
         Fig 40: Checking Clearance Between Synchronizer Ring And Gear

         Courtesy of FORD MOTOR CO.
CAUTION: To prevent damage, do not heat the mainshaft rear bearing, the countershaft or mainshaft rear thrust washer, the mainshaft bushing or the countershaft bushing higher than 150°C (300°F) maximum.
NOTE: Make sure the components are heated to 150°C (300 °F) for reassembly.
39. New or original components should be heated in advance of the assembly procedure. Heating will ease the assembly process. Place the mainshaft rear bearing, the countershaft rear thrust washer, the countershaft bushing, the rear mainshaft bearing, the and the mainshaft low gear bushing into the Gear/Bearing Heater.
40. Remove the interlock plate, the first/second and third/fourth shift fork and shift rail assemblies.
    Fig 41: Removing Interlock Plate

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41. Inspect all the shift fork pads and centers for wear or damage. Install new shift forks as necessary.
    Fig 42: Installing Shift Forks

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CAUTION: To prevent damage, do not heat the bearings higher than 150°C (300°F) maximum.
42. Inspect the mainshaft middle bearing, the countershaft middle bearing and the bearing cups in the intermediate housing for wear or damage. Install new components as necessary.
    • Always install new bearings and cups as a set. Do not install one without the other.
    • The bearings should be heated to install. Place the bearings in the Gear/Bearing Heater.
43. Remove the countershaft rear bearing spacer.
    Fig 43: Removing Countershaft Rear Bearing Spacer

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44. Remove the countershaft from the Gear Pack Assembly Fixture and set it aside.
    Fig 44: Removing Countershaft From Gear Pack Assembly Fixture

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