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

G03964711
 Installer, Clutch Housing Oil Seal 308-057 (T77J-7025-G)
G03964712
 Installer, Transmission Extension Housing Seal 308-002 (T61L-7657-A)
G03985709
 Staking Tool, Locknut 308-056 (T77J-7025-F)
MATERIAL CHART

Item Specification
MERCON® Multi-Purpose ATF Transmission Fluid XT-2-QDX MERCON®
Threadlock and Sealer TA-25 WSK-M2G351-A5
Gasket Maker TA-16 WSK-M2G348-A5
Ultra Silicone Sealant TA-29 -
  1. Install the countershaft.
    • Do not install the countershaft front or rear bearings at this time.
    Fig 1: Installing Countershaft
    G03964638Courtesy of FORD MOTOR CO.
  2. Position the input shaft into the transmission.
    Fig 2: Positioning Input Shaft Into Transmission
    G03964715Courtesy of FORD MOTOR CO.
    3. NOTE: Make sure the 4th gear synchronizer blocking ring and the bearings are in place.
    Fig 3: Installing Output Shaft And Mate Input Shaft And Output Shaft Together
    G03964636Courtesy of FORD MOTOR CO.
  3. Install the output shaft and mate the input shaft and output shaft together.
  4. Install the center countershaft bearing.
    Fig 4: Installing Center Countershaft Bearing
    G03964717Courtesy of FORD MOTOR CO.
  5. Install the output shaft center bearing.
    Fig 5: Installing Output Shaft Center Bearing
    G03964718Courtesy of FORD MOTOR CO.
    6. NOTE: Install the rear bearing retainer with the arrow pointing to the top of the case.
    Fig 6: Installing Rear Bearing Retainer And 6 Rear Bearing Retainer Bolts
    G03964625Courtesy of FORD MOTOR CO.
    NOTE: If any related parts (such as the output shaft or bearing) have been installed new, carry-out the shim thickness selective procedure.
  6. Install the rear bearing retainer and the 6 rear bearing retainer bolts.
    • Tighten to 22 Nm (16 lb-ft).
  7. Using the special tool, install the front cover oil seal.
    Fig 7: Using Special Tool To Install Front Cover Oil Seal
    G03964720Courtesy of FORD MOTOR CO.
  8. Position the transmission with the bellhousing facing up.
  9. Install the front countershaft bearing.
  10. Install the input shaft front bearing race.
    11. NOTE: A digital caliper is shown being used for the depth measurement. A dial indicator with depth capability or a depth micrometer can also be used.
    Fig 8: Measuring Input Shaft Bearing Race Height
    G03964721Courtesy of FORD MOTOR CO.
  11. Measure the input shaft bearing race height.
    • Record this measurement on line 2 of the selective shim equation chart.
  12. Measure the front bearing retainer depth.
    • Record this measurement on line 1 of the selective shim equation chart.
    Fig 9: Measuring Front Bearing Retainer Depth
    G03964722Courtesy of FORD MOTOR CO.
  13. Calculate the measurements.
    SELECTIVE SHIM EQUATION CHART

    Step Measurement mm (in)
    Line 1  
    Line 2  
    Line 3 (Subtract line 2 from line 1)  
    • Select the correct output shaft shim to achieve the correct end play. Output shaft end play is 0.05-0.15 mm (0.0019-0.0059 in).
    • Output shaft shim selection:
      • 1.4 mm (0.055 in)
      • 1.5 mm (0.059 in)
      • 1.6 mm (0.063 in)
      • 1.7 mm (0.067 in)
      • 1.8 mm (0.071 in)
      • 1.9 mm (0.075 in)
      • 2.0 mm (0.079 in)
      • 2.1 mm (0.083 in)
      • 2.2 mm (0.087 in)
      • 2.3 mm (0.090 in)
      • 2.4 mm (0.094 in)
      • 2.5 mm (0.098 in)
      • 2.6 mm (0.102 in)
      • 2.7 mm (0.106 in)
      • 2.8 mm (0.110 in)
      • 2.9 mm (0.114 in)
      • 3.0 mm (0.118 in)
  14. Measure and record the countershaft bearing depth.
    Fig 10: Measuring Countershaft Bearing Depth
    G03964723Courtesy of FORD MOTOR CO.
  15. Select the correct countershaft shim.
    • Select the appropriate spacer to achieve the correct end play. Countershaft end play is 0.15-0.25 mm (0.0059-0.0098 in).
    • Countershaft selection shims:
      • 3.0 mm (0.118 in)
      • 3.1 mm (0.122 in)
      • 3.2 mm (0.125 in)
      • 3.3 mm (0.129 in)
      • 3.4 mm (0.134 in)
      • 3.5 mm (0.138 in)
      • 3.6 mm (0.142 in)
      • 3.7 mm (0.146 in)
    16. NOTE: Apply a light coat of fluid or grease to the countershaft spacer, shim and fluid baffle.
    Fig 11: Installing Bearing Shim, Fluid Baffle And Countershaft Spacer Onto Front Bearing Retainer
    G03964724Courtesy of FORD MOTOR CO.
  16. Install the bearing shim, fluid baffle and countershaft spacer onto the front bearing retainer.
    17. NOTE: Apply a small amount of silicone sealer to the bolt threads.
    NOTE: Apply a light coat of fluid to the seal lips. Be careful not to damage the seal when installing the retainer.
    Fig 12: Installing Front Bearing Retainer (1 Of 2)
    G03964725Courtesy of FORD MOTOR CO.
    Fig 13: Installing Front Bearing Retainer (2 Of 2)
    G03964726Courtesy of FORD MOTOR CO.
  17. Install the front bearing retainer.
    • Tighten to 22 Nm (16 lb-ft).
    18. NOTE: Apply a small amount of silicone sealer to the bolt threads.
    Fig 14: Installing Fluid Passage And Fluid Passage Bolt
    G03964727Courtesy of FORD MOTOR CO.
  18. Install the fluid passage and the fluid passage bolt.
    • Tighten to 9 Nm (80 lb-in).
  19. Install the output shaft 5th speed gear.
    Fig 15: Installing Output Shaft 5th Speed Gear
    G03964728Courtesy of FORD MOTOR CO.
  20. Install the following components:
    • Locating ball
    • Inner race
    • 5th speed gear split bearing
    Fig 16: Installing 5th Speed Gear Split Bearing, Inner Race And Locating Ball
    G03964729Courtesy of FORD MOTOR CO.
  21. Install the countershaft 5th speed gear.
    Fig 17: Installing Countershaft 5th Speed Gear
    G03964730Courtesy of FORD MOTOR CO.
  22. Position the counter lever shaft and plate, then install the counter lever lock plate bolt.
    • Tighten to 9 Nm (80 lb-in).
    Fig 18: Installing Counter Lever Lock Plate Bolt
    G03964622Courtesy of FORD MOTOR CO.
  23. Install the 5th/reverse shift lever, the washer and the 5th/reverse shift retaining ring.
    Fig 19: Installing 5th/Reverse Shift Lever, Washer And 5th/Reverse Shift Retaining Ring
    G03964621Courtesy of FORD MOTOR CO.
  24. Install the countershaft 5th gear synchronizer blocking ring.
    Fig 20: Installing Countershaft 5th Gear Synchronizer Blocking Ring
    G03964733Courtesy of FORD MOTOR CO.
    25. NOTE: The reference mark on the synchronizer sleeve must face toward the reverse gear.
    Fig 21: Installing 5th/Reverse Shift Rail, Shift Fork And 5th/Reverse Synchronizer Assembly
    G03964734Courtesy of FORD MOTOR CO.
  25. Install the 5th/reverse shift rail, the shift fork and the 5th/reverse synchronizer assembly.
  26. Install the 5th/reverse shift rail bolt.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 22: Installing 5th/Reverse Shift Rail Bolt
    G03964616Courtesy of FORD MOTOR CO.
  27. Install the countershaft split washer.
    Fig 23: Installing Countershaft Split Washer
    G03964615Courtesy of FORD MOTOR CO.
  28. Check clutch hub end play.
    • If clutch hub end play is not within specification, select and install the correct split washer.
    • Split washer selection:
      • 3.0 mm (0.118 in)
      • 3.1 mm (0.122 in)
      • 3.2 mm (0.125 in)
      • 3.3 mm (0.129 in)
      • 3.4 mm (0.133 in)
      • 3.05 mm (0.120 in)
      • 3.15 mm (0.124 in)
      • 3.25 mm (0.127 in)
      • 3.35 mm (0.131 in)
    Fig 24: Checking Clutch Hub End Play
    G03964737Courtesy of FORD MOTOR CO.
  29. Install the reverse gear thrust washer.
    Fig 25: Installing Reverse Gear Thrust Washer
    G03964738Courtesy of FORD MOTOR CO.
  30. Install the following:
    1. Reverse synchronizer blocking ring
    2. Two countershaft reverse gear bearings
    3. Countershaft reverse gear
    Fig 26: Installing Countershaft Reverse Gear, Two Countershaft Reverse Gear Bearings And Reverse Synchronizer Blocking Ring
    G03964739Courtesy of FORD MOTOR CO.
  31. Measure the countershaft reverse gear end play.
    • Install the thrust washer and hold it against the shoulder on the countershaft while checking end play.
    • Determine the correct thrust washer to obtain correct end play.
    • Thrust washer selection:
      • 7.35 mm (0.289 in)
      • 7.45 mm (0.293 in)
      • 7.55 mm (0.297 in)
      • 7.65 mm (0.301 in)
      • 7.75 mm (0.305 in)
      • 7.85 mm (0.309 in)
    Fig 27: Measuring Countershaft Reverse Gear End Play
    G03964740Courtesy of FORD MOTOR CO.
  32. Install the output shaft spacer.
    Fig 28: Installing Output Shaft Spacer
    G03964741Courtesy of FORD MOTOR CO.
  33. Install the output shaft reverse gear.
    Fig 29: Installing Output Shaft Reverse Gear
    G03964742Courtesy of FORD MOTOR CO.
  34. Install the reverse idler gear and bushing.
    Fig 30: Installing Reverse Idler Gear And Bushing
    G03964610Courtesy of FORD MOTOR CO.
  35. Apply Threadlock and Sealer to the reverse idler shaft bolt, install the bolt.
    • Tighten to 98 Nm (72 lb-ft).
    Fig 31: Installing Reverse Idler Shaft Bolt
    G03964609Courtesy of FORD MOTOR CO.
  36. Position the output shaft rear bearing on the output shaft. Using the old output shaft locknut, install the output shaft rear bearing. Discard the nut.
    Fig 32: Using Old Output Shaft Locknut To Install Output Shaft Rear Bearing
    G03964748Courtesy of FORD MOTOR CO.
  37. Install the thrust washer and countershaft rear bearing.
    Fig 33: Installing Thrust Washer And Countershaft Rear Bearing
    G03964746Courtesy of FORD MOTOR CO.
  38. Lock the transmission into 1st and 3rd gear.
    Fig 34: Locking Transmission Into 1st And 3rd Gear
    G03964605Courtesy of FORD MOTOR CO.
  39. Install a new output shaft locknut.
    • Tighten to 245 Nm (181 lb-ft).
    Fig 35: Installing New Output Shaft Locknut
    G03964748Courtesy of FORD MOTOR CO.
  40. Install a new countershaft locknut.
    • Tighten to 162 Nm (119 lb-ft).
    Fig 36: Installing New Countershaft Locknut
    G03964749Courtesy of FORD MOTOR CO.
  41. Using the special tool, stake the output shaft locknut and the countershaft locknut.
    Fig 37: Using Special Tool To Stake Output Shaft Locknut And Countershaft Locknut
    G03964750Courtesy of FORD MOTOR CO.
  42. Position the locating ball on the shaft, install the output speed (OSS) tone ring, then install the snap ring.
  43. Apply a small bead of silicone rubber to the extension housing mating surface.
  44. Install the extension housing and the extension housing bolts.
    • Tighten to 39 Nm (29 lb-ft).
  45. Using the special tool, install a new extension housing seal.
    Fig 38: Using Special Tool To Install New Extension Housing Seal
    G03964751Courtesy of FORD MOTOR CO.
  46. Place the synchronizer sleeves in NEUTRAL.
    Fig 39: Placing Synchronizer Sleeves In NEUTRAL
    G03964752Courtesy of FORD MOTOR CO.
  47. Install the shift control housing seal.
    Fig 40: Installing Shift Control Housing Seal
    G03964600Courtesy of FORD MOTOR CO.
  48. Install the case cover and the case cover bolts.
    • Tighten to 19 Nm (14 lb-ft).
    Fig 41: Installing Case Cover And Case Cover Bolts
    G03964754Courtesy of FORD MOTOR CO.
  49. Install the clutch slave cylinder.
    • Tighten to 20 Nm (15 lb-ft).
    Fig 42: Installing Clutch Slave Cylinder
    G03964755Courtesy of FORD MOTOR CO.
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