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Section 1575 (Manual Transmission - F250-F550): Disassembly: Transmission

WARNING: This page is about a different car, the 2006 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOLS CHART

G04650438
 Fixture, Gear Pack
308-381
G04650439
 Holding Fixture, Drive Pinion Flange
205-126 (T78P-4851-A)
G04650440
 2 or 3 Jaw Puller
205-D027 (D80L-1013-A)
G04650441
 Remover, Jet Plug
310-005 (T77L-9533-B)
G04650442
 Shaft Protector Set
205-DS004 (D80L-625-A)
G04650443
 Gear/Bearing Heater
164R-3900
G04650444
 Remover/Installer, Front Wheel Hub
204-069 (T81P-1104-C)
G04650445
 Socket, Mainshaft Locknut (36 mm)
308-127 (T87P-7025-AH)
G04650446
 Centerplate Legs
308-380
MATERIAL CHART

Item Specification
MERCON® Multi-Purpose Automatic Transmission Fluid XT-2-QDX

    All vehicles 

    WARNING: Wear protective eyewear whenever using compressed air.
  1. Clean the transmission exterior with solvent and dry with compressed air.
    2. 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 1: Locating Clutch Release Lever And Clutch Release Hub
    G04650447Courtesy of FORD MOTOR CO.
    4. 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 2: Locating Transmission
    G04650448Courtesy of FORD MOTOR CO.
  4. Position the transmission on the floor with the output flange pointing upward.

    5. Rear wheel drive (RWD) vehicles 

  5. Using the special tools, remove the pinion flange.
    Fig 3: Identifying Special Tools
    G04650449Courtesy of FORD MOTOR CO.

    6. All vehicles 

  6. Remove the 19 bolts.
    Fig 4: Locating Bolts
    G04650450Courtesy of FORD MOTOR CO.
    7. 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 5: Identifying Special Tool
      G04650451Courtesy of FORD MOTOR CO.
  8. Remove the main shift detent.
    Fig 6: Locating Main Shift Detent
    G04650452Courtesy of FORD MOTOR CO.
  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 7: Locating Detent Plunger
      G04650453Courtesy of FORD MOTOR CO.
  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 8: Locating Extension Housing
      G04650454Courtesy of FORD MOTOR CO.
  11. Remove the intermediate housing to case bolts.
    Fig 9: Locating Intermediate Housing To Case Bolts
    G04650455Courtesy of FORD MOTOR CO.
  12. Using a suitable lifting device, a suitable chain and 2 S-hooks, lift the intermediate housing and gear assembly out of the main case.
    • Place the S-hooks in the intermediate housing where the 2 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 25 mm (1 in) off the ground. Using a soft-faced hammer, lightly tap the main housing to break the gasket seal.
      Fig 10: Lifting Transmission (1 Of 2)
      G04650456Courtesy of FORD MOTOR CO.
      Fig 11: Lifting Transmission (2 Of 2)
      G04650457Courtesy of FORD MOTOR CO.
  13. Position the intermediate housing and gear assembly on the special tool.
    • Securely fasten the holding plate to a sturdy work bench.
      Fig 12: Locating Intermediate Housing And Gear Assembly
      G04650458Courtesy of FORD MOTOR CO.
  14. Remove the low/reverse/5th gear main shift rail driver.
    1. Remove the 2 roll pins.
      • Use a hammer and punch or an air hammer and roll pin remover.
    2. Remove the main shift rail driver.
      Fig 13: Identifying Main Shift Rail Driver
      G04650459Courtesy of FORD MOTOR CO.
    15. NOTE: The shift finger is also the 1st/2nd and 3rd/4th 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 14: Locating Lower Roll Pins (1 Of 2)
      G04650460Courtesy of FORD MOTOR CO.
      Fig 15: Locating Lower Roll Pins (2 Of 2)
      G04650461Courtesy of FORD MOTOR CO.
  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 16: Identifying Main Shift Rail
      G04650462Courtesy of FORD MOTOR CO.
  17. Align the interlock plate into 2nd gear position, engage 2nd gear, then remove the two 5th gear shift fork roll pins.
    • Use a hammer and punch or an air hammer and roll pin remover to remove.
      Fig 17: Locating Roll Pin
      G04650463Courtesy of FORD MOTOR CO.
  18. Remove the 5th gear shift fork and shift rail.
    • Align the interlock plate into the 5th gear position. Remove the shift rail by tapping the shift fork with a soft-faced hammer while pulling up on the shift rail.
      Fig 18: Locating 5Th Gear Shift Fork And Shift Rail
      G04650464Courtesy of FORD MOTOR CO.
  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 19: Locating Reverse Gear Shift Fork Roll Pin
      G04650465Courtesy of FORD MOTOR CO.
  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 20: Locating Low/Reverse Gear Shift Fork And Shift Rail
      G04650466Courtesy 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 21: Locating Shift Rail Detents
      G04650467Courtesy of FORD MOTOR CO.
  22. On 4-wheel drive vehicles, remove and discard the snap ring.
    Fig 22: Locating Snap Ring
    G04650468Courtesy of FORD MOTOR CO.
  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 23: Identifying Special Tools
    G04650469Courtesy 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 24: Locating Mainshaft Rear Bearing
      G04650470Courtesy of FORD MOTOR CO.
  25. Remove the mainshaft needle bearings.
    • Inspect the bearings for wear or damage. Install new bearings as necessary.
      Fig 25: Locating Mainshaft Needle Bearings
      G04650471Courtesy of FORD MOTOR CO.
  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 26: Locating Low And Reverse Synchronizer
      G04650472Courtesy 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 27: Exploded View Of Low And Reverse Synchronizer Assembly
      G04650473Courtesy 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 28: Identifying Gap Between Ring And Gear
        G04650474Courtesy of FORD MOTOR CO.
  29. Remove the mainshaft needle bearing.
    Fig 29: Locating Mainshaft Needle Bearing
    G04650475Courtesy of FORD MOTOR CO.
  30. For vehicles equipped with a 6.0L engine, remove the low gear thrust washer.
    Fig 30: Locating Low Gear Thrust Washer
    G04650476Courtesy of FORD MOTOR CO.
  31. Remove and discard the snap ring.
    Fig 31: Locating Snap Ring
    G04650477Courtesy of FORD MOTOR CO.
  32. Remove the countershaft rear thrust washer.
    Fig 32: Locating Countershaft Rear Thrust Washer
    G04650478Courtesy of FORD MOTOR CO.
  33. Remove 5th gear.
    Fig 33: Locating 5Th Gear
    G04650479Courtesy of FORD MOTOR CO.
  34. Remove the countershaft needle bearing.
    Fig 34: Locating Countershaft Needle Bearing
    G04650480Courtesy of FORD MOTOR CO.
  35. Remove the interlock plate bolts.
    Fig 35: Locating Interlock Plate Bolts
    G04650481Courtesy of FORD MOTOR CO.
    36. 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 5th gear synchronizer assembly and the intermediate housing.
    • When installing the Centerplate Legs, position them opposing one another.
    • Inspect the countershaft 5th gear synchronizer, countershaft bushing and the intermediate plate for wear or damage. Install new components as necessary.
      Fig 36: Identifying Special Tools
      G04650482Courtesy of FORD MOTOR CO.
  37. Disassemble the countershaft 5th 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 37: Exploded View Of Countershaft 5Th Gear Synchronizer Assembly
      G04650483Courtesy 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 5th gear, install a new synchronizer assembly or 5th gear to obtain correct specification.
        Fig 38: Identifying Gap Between Ring And Gear
        G04650484Courtesy of FORD MOTOR CO.
    39. 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 and the mainshaft low gear bushing into the Gear/Bearing Heater.
  40. Remove the interlock plate, the 1st/2nd and 3rd/4th shift fork and shift rail assemblies.
    Fig 39: Removing Interlock Plate
    G04650485Courtesy of FORD MOTOR CO.
  41. Inspect all the shift fork pads and centers for wear or damage. Install new shift forks as necessary.
    Fig 40: Locating Shift Fork Pads And Centers
    G04650486Courtesy of FORD MOTOR CO.
    42. 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 41: Locating Countershaft Rear Bearing Spacer
    G04650487Courtesy of FORD MOTOR CO.
  44. Remove the countershaft from the Gear Pack Assembly Fixture and set it aside.
    Fig 42: Removing Countershaft From Gear Pack Assembly Fixture
    G04650488Courtesy of FORD MOTOR CO.
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