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Section 1875 (Manual Transmission - F-150): Disassembly: Transmission

WARNING: This page is about a different car, the 2007 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
Special Tools

Illustration Tool Name Tool Number
GF0001094
 Remover, Mainshaft Bearing 308-058 (T77J-7025-H)
GF0003878
 Remover, Front Cover 308-171 (T88T-7025-D)
GF0003879
 Socket, Transmission Shaft Locknut 308-168 (T88T-7025-AR)
GF0001068
 Remover/Installer, Bearing Tube 308-024 (T75L-7025-B)
GF0003880
 Removal Screw, Bearing Tube 308-092 (T84T-7025-B)
    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. Set the transmission on a work bench.
  4. Remove the case cover.
    • Remove the 10 shift control housing bolts.
    • Separate the shift control housing from the transmission.
    5. Fig 1: Locating Shift Control Housing Bolts
    GF0003881Courtesy of FORD MOTOR CO.
  5. Remove the shift control housing seal.
    6. Fig 2: Locating Shift Control Housing Seal
    GF0003882Courtesy of FORD MOTOR CO.
  6. Remove the extension housing.
    • Remove the 9 extension housing bolts.
    • Separate the extension housing from the transmission.
    7. Fig 3: Locating Extension Housing Bolts
    GF0003883Courtesy of FORD MOTOR CO.
  7. Remove the shipping seal.
    8. Fig 4: Locating Shipping Seal
    GF0003884Courtesy of FORD MOTOR CO.
  8. Remove the tone ring retaining ring and the vehicle speed sensor (VSS) tone ring.
    9. Fig 5: Locating Tone Ring Retaining Ring
    GF0003885Courtesy of FORD MOTOR CO.
  9. Remove the locating ball.
    10. Fig 6: Locating Ball
    GF0003886Courtesy of FORD MOTOR CO.
  10. Slide the 1st/2nd and 3rd/4th synchronizer sleeves forward to lock the transmission into 1st and 3rd gears.
    11. Fig 7: Locking Transmission Into 1st And 3rd Gear
    GF0003887Courtesy of FORD MOTOR CO.
    NOTE: Release the stake mark on the nut.
  11. Remove and discard the countershaft locknut.
    12. Fig 8: Locating Countershaft Locknut
    GF0003888Courtesy of FORD MOTOR CO.
  12. Remove the countershaft rear bearing and the countershaft rear bearing thrust washer.
    13. Fig 9: Removing Countershaft Rear Bearing
    GF0003889Courtesy of FORD MOTOR CO.
    NOTE: Release the stake mark on the nut.
  13. Using the special tool, remove the output shaft rear bearing locknut.
    14. Fig 10: Removing Output Shaft Rear Bearing Locknut
    GF0003890Courtesy of FORD MOTOR CO.
  14. Remove the reverse idler shaft bolt.
    15. Fig 11: Locating Reverse Idler Shaft Bolt
    GF0003891Courtesy of FORD MOTOR CO.
  15. Remove the reverse idler gear.
    16. Fig 12: Locating Reverse Idler Gear
    GF0003892Courtesy of FORD MOTOR CO.
  16. Using the special tools, remove the output shaft bearing.
    17. Fig 13: Removing Output Shaft Bearing
    GF0003893Courtesy of FORD MOTOR CO.
  17. Remove the output shaft reverse gear and bushing.
    18. Fig 14: Removing Output Shaft Reverse Gear And Bushing
    GF0003894Courtesy of FORD MOTOR CO.
  18. Remove the output shaft spacer.
    19. Fig 15: Locating Output Shaft Spacer
    GF0003895Courtesy of FORD MOTOR CO.
  19. Remove the following components:
    • Countershaft reverse gear
    • Two countershaft reverse gear bearings
    • Reverse synchronizer blocking ring
    • Reverse gear thrust washer
    20. Fig 16: Identifying Countershaft Reverse Gear Bearings And Thrust Washer
    GF0003896Courtesy of FORD MOTOR CO.
  20. Remove the countershaft split washer.
    21. Fig 17: Locating Countershaft Split Washer
    GF0003897Courtesy of FORD MOTOR CO.
  21. Remove the reverse gear shift rail bolt.
    22. Fig 18: Locating 5th/Reverse Shift Rail Bolt
    GF0003898Courtesy of FORD MOTOR CO.
  22. Remove the 5th/reverse synchronizer, the gear shifter fork and the reverse gear shift rail as an assembly.
    23. Fig 19: Locating 5th/Reverse Synchronizer
    GF0003899Courtesy of FORD MOTOR CO.
  23. Separate the gear shifter fork from the 5th/reverse synchronizer.
    24. Fig 20: Locating Gear Shifter Fork From 5th/Reverse Synchronizer
    GF0003900Courtesy of FORD MOTOR CO.
  24. Remove the countershaft 5th gear synchronizer blocking ring and 5th gear.
    25. Fig 21: Locating Countershaft 5th Gear Synchronizer Blocking Ring And 5th Gear
    GF0003901Courtesy of FORD MOTOR CO.
  25. Remove the following components:
    • Countershaft 5th gear split bearing
    • Inner race
    • Locating ball
    26. Fig 22: Removing Countershaft 5th Gear Split Bearing
    GF0003902Courtesy of FORD MOTOR CO.
  26. Remove the 5th/reverse shift lever retaining ring, the washer and the 5th/reverse shift lever.
    27. Fig 23: Locating 5th/Reverse Shift Lever Retaining Ring
    GF0003903Courtesy of FORD MOTOR CO.
  27. Remove the lock plate bolt, then slide the shaft out of the case.
    28. Fig 24: Locating Counter Lever Lock Plate Bolt
    GF0003904Courtesy of FORD MOTOR CO.
  28. Remove the output shaft 5th speed gear.
    29. Fig 25: Locating Output Shaft 5th Speed Gear
    GF0003905Courtesy of FORD MOTOR CO.
  29. Remove the 2 clutch slave cylinder bolts and the clutch slave cylinder.
    30. Fig 26: Locating Clutch Slave Cylinder Bolts
    GF0003906Courtesy of FORD MOTOR CO.
  30. Remove the rear bearing retainer bolts and the rear bearing retainer, then remove the rear countershaft bearing.
    31. Fig 27: Locating Rear Bearing Retainer Bolts
    GF0003907Courtesy of FORD MOTOR CO.
  31. 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.
    32. Fig 28: Removing Front Bearing Retainer Bolts
    GF0003908Courtesy of FORD MOTOR CO.
  32. Remove the fluid baffle shim.
    33. Fig 29: Locating Fluid Baffle Shim
    GF0003909Courtesy of FORD MOTOR CO.
  33. Remove the front bearing retainer seal.
    • Discard the seal.
    34. Fig 30: Locating Front Bearing Retainer Seal
    GF0003910Courtesy of FORD MOTOR CO.
  34. Remove the fluid baffle.
    35. Fig 31: Locating Fluid Baffle
    GF0003911Courtesy of FORD MOTOR CO.
  35. Remove the front countershaft bearing.
    36. Fig 32: Locating Front Countershaft Bearing
    GF0003912Courtesy of FORD MOTOR CO.
  36. Remove the fluid passage bolt.
    37. Fig 33: Locating Fluid Passage Bolt
    GF0003913Courtesy of FORD MOTOR CO.
  37. Remove the fluid passage.
    38. Fig 34: Locating Fluid Passage
    GF0003914Courtesy of FORD MOTOR CO.
  38. Remove the input shaft front bearing race.
    39. Fig 35: Locating Input Shaft Front Bearing Race
    GF0003915Courtesy of FORD MOTOR CO.
  39. Remove the output shaft center bearing race and the center countershaft bearing.
    40. Fig 36: Locating Output Shaft Center Bearing Race
    GF0003916Courtesy of FORD MOTOR CO.
  40. Separate the input shaft from the output shaft.
    • Move the countershaft rearward and rotate the input shaft to position the flat section downward.
    41. Fig 37: Locating Countershaft Rearward
    GF0003917Courtesy of FORD MOTOR CO.
  41. Remove the output shaft.
    • Move the countershaft down to gain room then remove the output shaft.
    42. Fig 38: Locating Output Shaft
    GF0003918Courtesy of FORD MOTOR CO.
  42. Remove the input shaft.
    43. Fig 39: Locating Input Shaft
    GF0003919Courtesy of FORD MOTOR CO.
  43. Remove the countershaft.
    44. Fig 40: Locating Countershaft
    GF0003920Courtesy of FORD MOTOR CO.
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