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

G03923481
 Fixture, Gear Pack 308-381
G03878572
 Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A)
G03984234
 2 or 3 Jaw Puller 205-D027 (D80L-1013-A)
G03923432
 Remover, Jet Plug 310-005 (T77L-9533-B)
G03923489
 Shaft Protector Set 205-DS004 (D80L-625-A)
G03923541
 Gear/Bearing Heater 164R-3900
G03918561
 Remover/Installer, Front Wheel Hub 204-069 (T81P-1104-C)
G03923436
 Socket, Mainshaft Locknut (36 mm) 308-127 (T87P-7025-AH)
G03923437
 Centerplate Legs 308-380
MATERIAL SPECIFICATIONS

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: Removing Clutch Release Lever And Clutch Release Hub And Bearing
    G03923438Courtesy 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: Positioning Transmission On Floor With Output Flange Pointing Upward
    G03923439Courtesy of FORD MOTOR CO.
  4. Position the transmission on the floor with the output flange pointing upward.

    5. 4x2 vehicles 

  5. Using the special tools, remove the pinion flange.
    Fig 3: Removing Pinion Flange
    G03923375Courtesy of FORD MOTOR CO.

    6. All vehicles 

  6. Remove the 19 bolts.
    Fig 4: Removing Bolts
    G03923441Courtesy 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: Removing Detent Plugs And Shift Detent Springs
      G03923442Courtesy of FORD MOTOR CO.
  8. Remove the main shift detent.
    Fig 6: Removing Main Shift Detent
    G03923443Courtesy 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: Inspecting Detent Plunger For Wear Or Damage
      G03923444Courtesy 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: Removing Extension Housing From Intermediate Housing
      G03923445Courtesy of FORD MOTOR CO.
  11. Remove the intermediate housing to case bolts.
    • Early production vehicles will have three bolts.
      Fig 9: Removing Intermediate Housing To Case Bolts (1 Of 2)
      G03923446Courtesy of FORD MOTOR CO.
      Fig 10: Removing Intermediate Housing To Case Bolts (2 Of 2)
      G03923447Courtesy of FORD MOTOR CO.
  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 25 mm (1 in) off the ground. Using a soft faced hammer, lightly tap the main housing to break the gasket seal.
      Fig 11: Lifting Intermediate Housing And Gear Assembly Out Of Main Case (1 Of 2)
      G03923448Courtesy of FORD MOTOR CO.
      Fig 12: Lifting Intermediate Housing And Gear Assembly Out Of Main Case (2 Of 2)
      G03923449Courtesy 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 13: Positioning Intermediate Housing And Gear Assembly On Special Tool
      G03923450Courtesy of FORD MOTOR CO.
  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 14: Removing Main Shift Rail Driver
      G03923451Courtesy of FORD MOTOR CO.
    15. 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 15: Removing Lower Roll Pins (1 Of 2)
      G03923452Courtesy of FORD MOTOR CO.
      Fig 16: Removing Lower Roll Pins (2 Of 2)
      G03923453Courtesy 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 17: Removing Main Shift Rail
      G03923454Courtesy of FORD MOTOR CO.
  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 18: Removing Two Fifth Gear Shift Fork Roll Pins
      G03923455Courtesy of FORD MOTOR CO.
  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 19: Removing Fifth Gear Shift Fork And Shift Rail
      G03923456Courtesy 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 20: Removing Low And Reverse Gear Shift Fork Roll Pin
      G03923457Courtesy 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 21: Removing Low/Reverse Gear Shift Fork And Shift Rail
      G03923458Courtesy 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 22: Removing Shift Rail Detents
      G03923459Courtesy of FORD MOTOR CO.
  22. On 4-wheel drive vehicles, remove and discard the snap ring.
    Fig 23: Removing Snap Ring
    G03923460Courtesy 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 24: Removing Mainshaft Assembly
    G03923461Courtesy 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 25: Removing Mainshaft Rear Bearing And Output Bearing Thrust Washer From Low And Reverse Assembly
      G03923462Courtesy of FORD MOTOR CO.
  25. Remove the mainshaft needle bearings.
    • Inspect the bearings for wear or damage. Install new bearings as necessary.
      Fig 26: Removing Mainshaft Needle Bearings
      G03923463Courtesy 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 27: Removing Low Gear From Low And Reverse Synchronizer Assembly
      G03923464Courtesy 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 28: Disassembling Low And Reverse Synchronizer Assembly
      G03923475Courtesy 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 29: Checking Clearance Between Synchronizer Ring And Gear
        G03923505Courtesy of FORD MOTOR CO.
  29. Remove the mainshaft needle bearing.
    Fig 30: Removing Mainshaft Needle Bearing
    G03923467Courtesy of FORD MOTOR CO.
  30. For vehicles equipped with a 6.0L engine, remove the low gear thrust washer.
    Fig 31: Removing Low Gear Thrust Washer
    G03923468Courtesy of FORD MOTOR CO.
  31. Remove and discard the snap ring.
    Fig 32: Removing Snap Ring
    G03923469Courtesy of FORD MOTOR CO.
  32. Remove the countershaft rear thrust washer.
    Fig 33: Removing Countershaft Rear Thrust Washer
    G03923470Courtesy of FORD MOTOR CO.
  33. Remove fifth gear.
    Fig 34: Removing Fifth Gear
    G03923471Courtesy of FORD MOTOR CO.
  34. Remove the countershaft needle bearing.
    Fig 35: Removing Countershaft Needle Bearing
    G03923472Courtesy of FORD MOTOR CO.
  35. Remove the interlock plate bolts.
    Fig 36: Removing Interlock Plate Bolts
    G03923473Courtesy 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 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 37: Removing Countershaft Bushing, Countershaft Fifth Gear Synchronizer Assembly And Intermediate Housing
      G03923474Courtesy of FORD MOTOR CO.
  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 38: Disassembling Countershaft Fifth Gear Synchronizer Assembly
      G03923475Courtesy 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 39: Checking Clearance Between Synchronizer Ring And Gear
        G03923505Courtesy 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 first/second and third/fourth shift fork and shift rail assemblies.
    Fig 40: Removing Interlock Plate, First/Second And Third/Fourth Shift Fork And Shift Rail Assemblies
    G03923477Courtesy of FORD MOTOR CO.
  41. Inspect all the shift fork pads and centers for wear or damage. Install new shift forks as necessary.
    Fig 41: Inspecting All Shift Fork Pads And Centers For Wear Or Damage
    G03923478Courtesy 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 42: Removing Countershaft Rear Bearing Spacer
    G03923479Courtesy of FORD MOTOR CO.
  44. Remove the countershaft from the Gear Pack Assembly Fixture and set it aside.
    Fig 43: Removing Countershaft From Gear Pack Assembly Fixture
    G03923480Courtesy of FORD MOTOR CO.
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