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Section 904 (Manual Transmission -- F250-F550 Super Duty): Assembly: Transmission

WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOLS SPECIFICATIONS

G03923541
 Gear/Bearing Heater 164-R3900
G03923611
 Heat Gun 107-R0300 or equivalent
G03923481
 Fixture, Gear Pack 308-381
G03960920
 Remover, Bearing Cup 308-047 (T77F-1102-A)
G03923580
 Installer, Countershaft Front Bearing Cup 308-390
G03923591
 Handle 205-D055 (D81L-4000-A)
G03923616
 Installer, Input Shaft Bearing Cup 308-391
G03923553
 Remover, Input Shaft Bearing Cup 308-S392
G03991742
 Remover/Installer, Thrust Washer Bearing Cup 308-416
G03923368
 Installer, Output Shaft Oil Seal (4x4) 308-383
G03923620
 Installer, Output Shaft Oil Seal (4x2) 308-382
G03923621
 Installer, Input Shaft Oil Seal 308-379
G03878572
 Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A)
G03923436
 Socket, Mainshaft Locknut (36mm) 308-127 (T87T-7025-AH)
G03923624
 Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C)
G03883754
 Gauge, Clutch Housing 308-021 (T75L-4201-A)
MATERIAL SPECIFICATIONS

Item Specification
MERCON® Multi-Purpose Automatic Transmission Fluid MERCON®
Gasket Maker F8AZ-19B508-AB WSK-M2G348-A5
Threadlock and Sealer E0AZ-19554-AA WSK-M2G351-A5
Gasket and Trim Adhesive F3AZ-19B508-AA -
Threadlock 262 E2FZ-19554-B WSK-M2G351-A6
Premium Long Life Grease XG-l-C ESA-M1C75-B
    CAUTION: Do not reassemble the transmission dry. Apply lubricant throughout the assembly procedure.
  1. Lubricate all bearings, gears and synchronizers with the recommended transmission lubricant during reassembly.
  2. Index-mark the countershaft in relation to the oil pump slot.
    Fig 1: Aligning Index-Mark Countershaft In Relation To Oil Pump Slot (1 Of 2)
    G03923626Courtesy of FORD MOTOR CO.
    Fig 2: Aligning Index-Mark Countershaft In Relation To Oil Pump Slot (2 Of 2)
    G03923627Courtesy of FORD MOTOR CO.
  3. Position the countershaft to the mainshaft on the Gear Pack Assembly Fixture.
    Fig 3: Positioning Countershaft To Mainshaft On Gear Pack Assembly Fixture
    G03923628Courtesy of FORD MOTOR CO.
  4. Install the countershaft rear bearing spacer.
    • The countershaft rear bearing spacer can be installed either way.
      Fig 4: Installing Countershaft Rear Bearing Spacer
      G03923629Courtesy of FORD MOTOR CO.
  5. Install the first/second and third/fourth shift fork and shift rail assemblies.
    • The detent groove on the rail faces upward or to the output shaft.
    • All shift forks and rails use double roll pins.
      Fig 5: Installing First/Second, Third/Fourth Shift Fork And Shift Rail Assemblies
      G03923630Courtesy of FORD MOTOR CO.
  6. Install the interlock plate.
    • The stamped part numbers on the interlock plate must face toward the input shaft.
      Fig 6: Installing Interlock Plate
      G03923631Courtesy of FORD MOTOR CO.
  7. Install and position the intermediate housing on the mainshaft, the countershaft, and the shift rails.
    • Make sure the detents are clear of the bore area on the intermediate housing.
      Fig 7: Installing Intermediate Housing On Mainshaft, Countershaft, And Shift Rails
      G03923632Courtesy of FORD MOTOR CO.
  8. Install the interlock plate bolts.
    Fig 8: Identifying Tightening Torque Of Interlock Plate Bolts
    G03923633Courtesy of FORD MOTOR CO.
  9. Assemble the fifth gear synchronizer assembly.
    Fig 9: Assembling Fifth Gear Synchronizer Assembly
    G03923634Courtesy of FORD MOTOR CO.
  10. Install the fifth gear synchronizer assembly.
    • Install the fifth gear synchronizer with the snap ring on the synchronizer body facing down against the intermediate housing.
    • The fifth gear synchronizer will slide into place and does not require heat to install.
      Fig 10: Installing Fifth Gear Synchronizer Assembly
      G03923635Courtesy of FORD MOTOR CO.
    11. CAUTION: To prevent damage, do not heat the countershaft bushing higher than 150°C (300°F) maximum.
    Fig 11: Removing Countershaft Bushing From Gear/Bearing Heater
    G03923636Courtesy of FORD MOTOR CO.
  11. Remove the countershaft bushing from the Gear/Bearing Heater, then install the countershaft bushing.
    12. NOTE: Allow the countershaft bushing to cool for 2-4 minutes before installing the countershaft needle bearing.
    Fig 12: Installing Countershaft Needle Bearing
    G03923637Courtesy of FORD MOTOR CO.
  12. Install the countershaft needle bearing.
  13. Install the fifth gear.
    Fig 13: Installing Fifth Gear
    G03923638Courtesy of FORD MOTOR CO.
  14. Install the countershaft rear thrust washer and a new snap ring.
    • The snap ring is a selective fit. The correct snap ring should completely fill the groove when seated.
    • Install the snap ring with the small holes upward.
    • Make sure the snap ring is completely seated, with one tab of the snap ring under the gear tooth.
      Fig 14: Installing Countershaft Rear Thrust Washer And Snap Ring
      G03923639Courtesy of FORD MOTOR CO.
  15. For vehicles equipped with a 6.0L engine, install the low gear thrust washer.
    Fig 15: Installing Low Gear Thrust Washer
    G03923468Courtesy of FORD MOTOR CO.
  16. Install the two mainshaft low gear needle bearings.
    Fig 16: Installing Mainshaft Low Gear Needle Bearings
    G03923641Courtesy of FORD MOTOR CO.
  17. Install low gear.
    Fig 17: Installing Low Gear
    G03923642Courtesy of FORD MOTOR CO.
  18. Install the low and reverse synchronizer assembly and synchronizer ring.
    • Install the low/reverse gear synchronizer with the shoulder of the sliding sleeve facing down to the low gear.
    • The low/reverse synchronizer body will slide into place and does not require heat to install.
      Fig 18: Installing Low And Reverse Synchronizer Assembly And Synchronizer Ring
      G03923643Courtesy of FORD MOTOR CO.
    19. CAUTION: To prevent damage, do not heat the reverse gear bushing higher than 150°C (300°F) maximum.
    Fig 19: Removing Mainshaft Reverse Gear Bushing From Gear/Bearing Heater
    G03923644Courtesy of FORD MOTOR CO.
  19. Remove the mainshaft reverse gear bushing from the Gear/Bearing Heater, then install the mainshaft bushing.
    20. NOTE: Allow the mainshaft reverse gear bushing to cool for 2-4 minutes before installing mainshaft needle bearing.
    Fig 20: Installing Mainshaft Needle Bearing
    G03923645Courtesy of FORD MOTOR CO.
  20. Install the mainshaft needle bearing.
  21. Install the reverse gear. Pull the synchronizer sliding sleeve into the neutral position.
    Fig 21: Installing Reverse Gear
    G03923646Courtesy of FORD MOTOR CO.
    22. CAUTION: To prevent damage, do not heat the output bearing thrust washer higher than 150°C (300°F) maximum.
    Fig 22: Installing Output Bearing Thrust Washer
    G03923647Courtesy of FORD MOTOR CO.
  22. Remove the output bearing thrust washer from the Gear/Bearing Heater, then using the special tools, install the output bearing thrust washer.
    23. CAUTION: To prevent damage, do not heat the rear mainshaft output bearing higher than 150°C (300°F) maximum.
    Fig 23: Installing Rear Mainshaft Output Bearing
    G03923648Courtesy of FORD MOTOR CO.
  23. Remove the mainshaft output bearing from the Gear/Bearing Heater, then using the special tools, install the rear mainshaft output bearing.
  24. Using the Dial Indicator with Bracketry and the Clutch Housing Gauge, check the axial gear clearance at fifth gear.
    • If not within specifications, disassemble and reinspect.
      Fig 24: Checking Axial Gear Clearance At Fifth Gear
      G03923649Courtesy of FORD MOTOR CO.
  25. Using the Dial Indicator with Bracketry and the Clutch Housing Gauge, check the axial gear clearance at low gear.
    • If not within specifications, disassemble and reinspect.
      Fig 25: Checking Axial Gear Clearance At Low Gear
      G03923650Courtesy of FORD MOTOR CO.
  26. Using the Dial Indicator with Bracketry and the Clutch Housing Gauge, check the axial gear clearance at reverse gear.
    • If not within specifications, disassemble and reinspect.
      Fig 26: Checking Axial Gear Clearance At Reverse Gear
      G03923651Courtesy of FORD MOTOR CO.
    27. NOTE: The snap ring is used on 4-wheel drive vehicles only.
  27. Install a new snap ring.
    • The snap ring is a selective fit. The correct snap ring should completely fill the groove when seated.
    • Install the snap ring with the small holes upward.
      Fig 27: Installing Snap Ring
      G03923460Courtesy of FORD MOTOR CO.
    28. NOTE: Using an oil stone or emery cloth, lightly condition the shift rails and clean them with transmission fluid before installing the shift forks and shift rails.
    NOTE: Move the interlock plate into the fifth gear position.
    Fig 28: Installing Fifth Gear Shift Fork And Shift Rail
    G03923653Courtesy of FORD MOTOR CO.
  28. Install the fifth gear shift fork and the shift rail.
  29. Using a 5-mm (3/16-in) punch, align the roll pin hole with the top hole of the shift fork. Install the double roll pin in the lower hole, then install a roll pin in the upper hole.
    • Do not hit the sealing surface of the intermediate plate.
    • Make sure the slot of the roll pin is facing away from the shift rail.
      Fig 29: Aligning Roll Pin Hole With Top Hole Of Shift Fork
      G03923654Courtesy of FORD MOTOR CO.
    30. NOTE: Using an oil stone or emery cloth, lightly condition the shift rails and clean them with transmission fluid before installing the shift forks and rails.
    NOTE: Move the interlock plate into the low/reverse position.
    Fig 30: Installing Low/Reverse Gear Shift Fork And Shift Rail
    G03923655Courtesy of FORD MOTOR CO.
  30. Install the low/reverse gear shift fork and the shift rail.
  31. Using a 5-mm (3/16-in) punch, align the roll pin hole with the top hole of the shift fork. Install the double roll pin in the lower hole, then install a roll pin in the upper hole.
    • Make sure the slot of the roll pin is facing away from the shift rail.
      Fig 31: Installing Double Roll Pin In Lower Hole
      G03923656Courtesy of FORD MOTOR CO.
  32. Install the four shift detent springs and four new detent plugs.
    • Apply gasket maker to the detent plugs before installing.
      Fig 32: Installing Four Shift Detent Springs And Detent Plugs
      G03923657Courtesy of FORD MOTOR CO.
  33. Install the main shift rail, aligning the center of the interlock driver with the center of the interlock plate.
    • The part numbers on the main shift rail, shift position block and shift finger face the output side of the transmission. The roll pin groove on the main shift rail with the shorter distance from the end faces the output end.
      Fig 33: Installing Main Shift Rail
      G03923658Courtesy of FORD MOTOR CO.
  34. Install the lower shift finger and a new large roll pin, then install a new small roll pin.
    • Make sure the lower shift finger cup is down.
    • Install the large roll pin with the opening away from the gearset.
    • Make sure the center of the interlock driver is aligned with the center of the interlock plate before installing the small pin.
    • Install the small roll pin with the opening 180 degrees from the opening in the large roll pin. The roll pin should extend equally from both sides when properly installed.
      Fig 34: Installing Lower Shift Finger And Large Roll Pin
      G03923659Courtesy of FORD MOTOR CO.
  35. Install the main shift rail driver and a new large roll pin, then install a new small roll pin.
    • Install the large roll pin with the opening away from the gearset.
    • Install the small roll pin with the opening 180 degrees from the opening in the large roll pin.
      Fig 35: Installing Main Shift Rail Driver And Large Roll Pin
      G03923660Courtesy of FORD MOTOR CO.
    36. NOTE: Only install the bearing cups in the main case. The following bearing preload adjustment procedure will determine the thickness of the shim to be used.
    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.
  36. Place the main case on the floor. Align the oil pump center shaft with the slot in the countershaft.
    37. NOTE: Do not apply sealer at this time.
    NOTE: Do not damage the input shaft when removing it from the Gear Pack Assembly Fixture.
    NOTE: To aid installation, have an assistant lower the assembly while another guides the assembly into the main case.
  37. Using a suitable lifting device, a suitable chain and two S -hooks, lift the intermediate housing and gear assembly into the case.
    • Using the index mark made on the countershaft, make sure the oil pump center shaft is aligned with the slot on the countershaft.
    • Lightly tap the intermediate housing onto the transmission case.
      Fig 36: Lifting Intermediate Housing And Gear Assembly Into Case
      G03923448Courtesy of FORD MOTOR CO.
  38. Install the bolts.
    • Early production vehicles will have three bolts.
      Fig 37: Identifying Tightening Torque Of Intermediate Housing To Case Bolts
      G03923662Courtesy of FORD MOTOR CO.
  39. Install the special tools to measure countershaft clearance.
    • Mount the indicator stand to the intermediate housing.
    • Install the Dial Indicator Gauge. Make sure the indicator is off center on the end of the countershaft.
    • Zero the dial indicator.
      Fig 38: Measuring Countershaft Clearance
      G03923663Courtesy of FORD MOTOR CO.
    40. NOTE: The tool is installed on the PTO opening.
  40. Using the special tool, measure for countershaft clearance.
    • Lift up on the third gear counter.
    • Observe the dial indicator reading.
    • Add preload specification 0.02 mm (0.00079 in) and 0.09 mm (0.0035 in) to the dial indicator reading to determine shim thickness range. Countershaft clearance + 0.02 mm (0.00079 in) Preload = Shim size. Countershaft clearance + 0.09 mm (0.0035 in) Preload = Shim size. Choose the shim between the calculated values for the correct preload.
      Fig 39: Measuring Countershaft Clearance
      G03923664Courtesy of FORD MOTOR CO.
  41. Install the special tools to measure mainshaft clearance.
    • Mount the indicator stand to the intermediate housing.
    • Install the Dial Indicator Gauge. Make sure the indicator is off center on the end of the mainshaft.
    • Zero the dial indicator.
      Fig 40: Measuring Mainshaft Clearance (1 Of 2)
      G03923665Courtesy of FORD MOTOR CO.
  42. Lifting up on the mainshaft, measure the mainshaft clearance.
    • Lift up on low gear.
    • Observe the dial indicator reading.
    • Add preload specification 0.02 mm (0.00079 in) and 0.09 mm (0.0035 in) to the dial indicator reading to determine shim thickness. Measure the thickness of the input shaft oil dam bearing ring at three places and subtract the highest dimension. Mainshaft clearance (-) the thickness of the oil dam + 0.02 mm (0.00079 in) Preload = Shim size. Mainshaft clearance (-) the thickness of the oil dam + 0.09 mm (0.0035 in) Preload = Shim size. Choose the shim between the calculated values for the correct preload.
      Fig 41: Measuring Mainshaft Clearance (2 Of 2)
      G03923666Courtesy of FORD MOTOR CO.
  43. Remove the special tools, then remove the bolts.
    Fig 42: Removing Intermediate Housing To Case Bolts
    G03923446Courtesy of FORD MOTOR CO.
  44. Using a suitable lifting device, a suitable chain and two S-hooks, lift the intermediate housing and gear assembly out of the case.
    • Place the S-hooks in the area where the bolts were removed.
      Fig 43: Lifting Intermediate Housing And Gear Assembly Out Of Case
      G03923448Courtesy of FORD MOTOR CO.
  45. Using the special tools, remove the input shaft bearing cup.
    Fig 44: Removing Input Shaft Bearing Cup
    G03923669Courtesy of FORD MOTOR CO.
  46. Using the special tools, remove the countershaft bearing cup.
    Fig 45: Removing Countershaft Bearing Cup
    G03923670Courtesy of FORD MOTOR CO.
    47. NOTE: Use a Heat Gun on the case bearing cup area to aid installation.
  47. Install the new shim, the new input shaft oil dam bearing ring and the oil trough into the bearing cup bore, then using the special tools, install the input shaft bearing cup.
    • Using the clearance measurement plus the preload, select the appropriate shim and input shaft oil dam bearing ring.
      Fig 46: Installing Input Shaft Bearing Cup
      G03923572Courtesy of FORD MOTOR CO.
    48. NOTE: Use a Heat Gun on the case bearing cup area to aid installation.
  48. Install the new shim, then using the special tools, install the countershaft bearing cup.
    • Using the clearance measurement plus the preload, select the appropriate shim.
      Fig 47: Installing Countershaft Bearing Cup
      G03923573Courtesy of FORD MOTOR CO.
    49. CAUTION: Use an oil stone or sanding block to clean the intermediate plate and main case mating surfaces.
    CAUTION: Do not use a silicone sealing compound.
    NOTE: Do not wait longer than ten minutes to tighten the two bolts due to the rapid cure time of the sealant.
  49. Thinly coat the rear sealing surface of the case and the front sealing surface of the intermediate housing with gasket maker.
    50. 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.
    NOTE: To aid installation, have an assistant lower the assembly while another guides the assembly into the case.
  50. Install the intermediate housing and gear assembly into the case.
    • Using the index mark made on the countershaft, make sure the oil pump center shaft is aligned with the slot on the countershaft.
    • Lightly tap the intermediate housing onto the transmission case.
      Fig 48: Installing Intermediate Housing And Gear Assembly Into Case
      G03923448Courtesy of FORD MOTOR CO.
  51. Install the bolts.
    • Apply threadlock and sealer to the intermediate housing bolts.
      Fig 49: Identifying Tightening Torque Of Intermediate Housing Bolts
      G03923662Courtesy of FORD MOTOR CO.
    52. CAUTION: Do not use a silicone sealing compound.
    NOTE: Do not wait longer than ten minutes to tighten the bolts due to the rapid cure time of the sealant.
    Fig 50: Identifying Tightening Torque Of Extension Housing Bolts
    G03923675Courtesy of FORD MOTOR CO.
  52. Thinly coat the rear sealing surface of the intermediate housing and the extension housing with gasket maker. Install the extension housing.
  53. Apply threadlock and sealer to the threads of the main shift detent. Install the detent plunger and the main shift detent.
    Fig 51: Identifying Tightening Torque Of Main Shift Detent
    G03923676Courtesy of FORD MOTOR CO.
    54. NOTE: Cross tighten the bolts.
    Fig 52: Identifying Tightening Torque Of PTO Cover Bolts
    G03923677Courtesy of FORD MOTOR CO.
  54. Apply threadlock and sealer to the threads of the PTO cover bolts. Install a new gasket and the PTO cover.
  55. Using the special tool, install a new input oil seal.
    • Coat the outer diameter of the new input oil seal with gasket and trim adhesive.
    • Coat the inner diameter of the new input oil seal with MERCON®.
      Fig 53: Installing Input Oil Seal
      G03923678Courtesy of FORD MOTOR CO.
  56. Apply threadlock and sealer to the threads of the guide tube bolts. Install the guide tube.
    Fig 54: Identifying Tightening Torque Of Guide Tube Bolts
    G03923679Courtesy of FORD MOTOR CO.
  57. Install the release lever and clutch release hub and bearing.
    • Lubricate the ball stud and the clutch release lever. Only apply grease where the clutch release lever comes in contact with the pivot and the release hub and bearing.
      Fig 55: Installing Release Lever And Clutch Release Hub And Bearing
      G03923438Courtesy of FORD MOTOR CO.
  58. Coat the outer diameter of the new output oil seal with gasket and trim adhesive. Using the special tool, install a new output oil seal.
    Fig 56: Installing Output Oil Seal (1 Of 2)
    G03923681Courtesy of FORD MOTOR CO.
    Fig 57: Installing Output Oil Seal (2 Of 2)
    G03923682Courtesy of FORD MOTOR CO.
    59. NOTE: This step is for 2-wheel drive vehicles only.
    Fig 58: Identifying Tightening Torque Of Pinion Flange Lock Nut
    G03923683Courtesy of FORD MOTOR CO.
  59. Apply Threadlock 262 to the threads of the transmission flange lock nut. Using the holding fixture and the mainshaft locknut socket, install the transmission flange and a new pinion flange lock nut.
  60. Install the shifter.
    • Shift the transmission through all gears to make sure gears shift correctly.
  61. Check transmission preload. Shift the transmission into reverse and rotate the mainshaft.
    • Drag torque should be 2-8 Nm.
  62. Remove the shifter for installation.
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