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Section 925 (Manual Transmission - F-150): Assembly: Transmission

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Special Tools

Illustration Tool Name Tool Number
GF0003968
 Installer, Clutch Housing Oil Seal 308-057 (T77J-7025-G)
GF0000966
 Installer, Transmission Extension Housing Seal 308-002 (T61L-7657-A)
GF0001028
 Staking Tool, Locknut 308-056 (T77J-7025-F)
Material

Item Specification
MERCON® Multi-Purpose Automatic Transmission Fluid
XT-2-QDX (US); XT-2-LM12 (Canada)		 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.
    2. Fig 1: Locating Countershaft
    GF0003920Courtesy of FORD MOTOR CO.
  2. Position the input shaft into the transmission.
    3. Fig 2: Locating Input Shaft & Bearing
    GF0003969Courtesy of FORD MOTOR CO.
    NOTE: Make sure the 4th gear synchronizer blocking ring and the bearings are in place.
  3. Install the output shaft and mate the input shaft and output shaft together.
  4. Install the center countershaft bearing.
    5. Fig 3: Locating Output Shaft
    GF0003918Courtesy of FORD MOTOR CO.
    Fig 4: Identifying Center Countershaft Bearing
    GF0003970Courtesy of FORD MOTOR CO.
  5. Install the output shaft center bearing.
    6. Fig 5: Installing Output Shaft Center Bearing
    GF0003971Courtesy of FORD MOTOR CO.
    NOTE: Install the rear bearing retainer with the arrow pointing to the top of the case.
    NOTE: If any related parts (such as the output shaft or bearing) have been installed new, carry-out the shim thickness selective procedure.
    Fig 6: Locating Rear Bearing Retainer Bolts
    GF0003907Courtesy of FORD MOTOR CO.
  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.
    8. Fig 7: Installing Front Cover Oil Seal
    GF0003972Courtesy 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
    GF0003973Courtesy 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.
    13. Fig 9: Measuring Front Bearing Retainer Depth
    GF0003974Courtesy 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.
    15. Fig 10: Measuring Countershaft Bearing Depth
    GF0003975Courtesy 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.
  16. Install the bearing shim, fluid baffle and countershaft spacer onto the front bearing retainer.
    17. Fig 11: Locating Bearing Shim, Fluid Baffle And Countershaft Spacer
    GF0003976Courtesy of FORD MOTOR CO.
    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.
  17. Install the front bearing retainer.
    • Tighten to 22 Nm (16 lb-ft).
    18. Fig 12: Locating Front Bearing Retainer
    GF0003977Courtesy of FORD MOTOR CO.
    NOTE: Apply a small amount of silicone sealer to the bolt threads.
  18. Install the fluid passage and the fluid passage bolt.
    • Tighten to 9 Nm (80 lb-in).
    19. Fig 13: Locating Fluid Passage
    GF0003978Courtesy of FORD MOTOR CO.
    Fig 14: Locating Fluid Passage Bolt
    GF0003979Courtesy of FORD MOTOR CO.
  19. Install the output shaft 5th speed gear.
    20. Fig 15: Locating Output Shaft 5th Speed Gear
    GF0003980Courtesy of FORD MOTOR CO.
  20. Install the following components:
    • Locating ball
    • Inner race
    • 5th speed gear split bearing
    21. Fig 16: Locating 5th Speed Gear Split Bearing And Ball
    GF0003981Courtesy of FORD MOTOR CO.
  21. Install the countershaft 5th speed gear.
    22. Fig 17: Identifying Countershaft 5th Speed Gear
    GF0003982Courtesy 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: Locating Counter Lever Lock Plate Bolt
    GF0003904Courtesy of FORD MOTOR CO.
  23. Install the 5th/reverse shift lever, the washer and the 5th/reverse shift retaining ring.
    24. Fig 19: Locating 5th/Reverse Shift Lever Retaining Ring
    GF0003903Courtesy of FORD MOTOR CO.
  24. Install the countershaft 5th gear synchronizer blocking ring.
    25. Fig 20: Identifying Countershaft 5th Gear Synchronizer Blocking Ring
    GF0003983Courtesy of FORD MOTOR CO.
    NOTE: The reference mark on the synchronizer sleeve must face toward the reverse gear.
  25. Install the 5th/reverse shift rail, the shift fork and the 5th/reverse synchronizer assembly.
    26. Fig 21: Locating Shift Fork And 5th/Reverse Synchronizer Assembly
    GF0003984Courtesy of FORD MOTOR CO.
  26. Install the 5th/reverse shift rail bolt.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 22: Locating 5th/Reverse Shift Rail Bolt
    GF0003898Courtesy of FORD MOTOR CO.
  27. Install the countershaft split washer.
    28. Fig 23: Locating Countershaft Split Washer
    GF0003897Courtesy 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.
    Fig 24: Checking Clutch Hub End Play
    GF0003985Courtesy of FORD MOTOR CO.
    • 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)
  29. Install the reverse gear thrust washer.
    30. Fig 25: Installing Reverse Gear Thrust Washer
    GF0003986Courtesy of FORD MOTOR CO.
  30. Install the following:
    • Reverse synchronizer blocking ring
    • Two countershaft reverse gear bearings
    • Countershaft reverse gear
    31. Fig 26: Installing Reverse Synchronizer Blocking Ring
    GF0003987Courtesy 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.
      • Fig 27: Measuring Countershaft Reverse Gear End Play
      GF0003988Courtesy of FORD MOTOR CO.
    • 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)
  32. Install the output shaft spacer.
    33. Fig 28: Identifying Output Shaft Spacer
    GF0003989Courtesy of FORD MOTOR CO.
  33. Install the output shaft reverse gear.
    34. Fig 29: Identifying Output Shaft Reverse Gear
    GF0003990Courtesy of FORD MOTOR CO.
  34. Install the reverse idler gear and bushing.
    35. Fig 30: Locating Reverse Idler Gear
    GF0003892Courtesy 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: Locating Reverse Idler Shaft Bolt
      GF0003891Courtesy 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.
    37. Fig 32: Locating Output Shaft Locknut
    GF0003991Courtesy of FORD MOTOR CO.
  37. Install the thrust washer and countershaft rear bearing.
    38. Fig 33: Installing Thrust Washer And Countershaft Rear Bearing
    GF0003992Courtesy of FORD MOTOR CO.
  38. Lock the transmission into 1st and 3rd gear.
    39. Fig 34: Locking Transmission Into 1st And 3rd Gear
    GF0003887Courtesy of FORD MOTOR CO.
  39. Install a new output shaft locknut.
    • Tighten to 245 Nm (181 lb-ft).
      • Fig 35: Locating Output Shaft Locknut
      GF0003991Courtesy of FORD MOTOR CO.
  40. Install a new countershaft locknut.
    • Tighten to 162 Nm (119 lb-ft).
    Fig 36: Locating Countershaft Locknut
    GF0003993Courtesy of FORD MOTOR CO.
  41. Using the special tool, stake the output shaft locknut and the countershaft locknut.
    42. Fig 37: Locating Output Shaft Locknut And Countershaft Locknut
    GF0003994Courtesy 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.
    46. Fig 38: Installing New Extension Housing Seal
    GF0003995Courtesy of FORD MOTOR CO.
  46. Place the synchronizer sleeves in NEUTRAL.
    47. Fig 39: Locating Synchronizer Sleeves In Neutral
    GF0003996Courtesy of FORD MOTOR CO.
  47. Install the shift control housing seal.
    48. Fig 40: Locating Shift Control Housing Seal
    GF0003882Courtesy of FORD MOTOR CO.
  48. Install the case cover and the case cover bolts.
    • Tighten to 19 Nm (14 lb-ft).
    Fig 41: Locating Case Cover Bolts
    GF0003997Courtesy of FORD MOTOR CO.
  49. Install the clutch slave cylinder.
    • Tighten to 20 Nm (15 lb-ft).
      • Fig 42: Locating Clutch Slave Cylinder
      GF0003998Courtesy of FORD MOTOR CO.
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