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Section 1848 (Manual Transmission - ZF S6-650 & M6HD - 6-Speed -- F250-F550 Super Duty (2007)): Assembly: Transmission

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Special Tools

Illustration Tool Name Tool Number
GF0007210
 Gear/Bearing Heater 164-R3900
GF0000143
 Heat Gun 107-R0300 or equivalent
GF0007207
 Fixture, Gear Pack 308-381
GF0003256
 Remover, Bearing Cup 308-047 (T77F-1102-A)
GF0001210
 Installer, Countershaft Front Bearing Cup 308-390
GF0007304
 Handle 205-D055 (D81L-4000-A)
GF0007305
 Installer, Input Shaft Bearing Cup 308-391
GF0007303
 Remover, Input Shaft Bearing Cup 308-S392
GF0007296
 Remover/Installer, Thrust Washer Bearing Cup 308-416
GF0007167
 Installer, Output Shaft Oil Seal (Four Wheel Drive [4WD]) 308-383
GF0007168
 Installer, Output Shaft Oil Seal (Rear Wheel Drive [RWD]) 308-382
GF0007346
 Installer, Input Shaft Oil Seal 308-379 (Gas engines only)
GF0000772
 Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A)
GF0007170
 Socket, Mainshaft Locknut (36mm) 308-127 (T87T-7025-AH)
GF0001072
 Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C)
GF0000771
 Gauge, Clutch Housing 308-021 (T75L-4201-A)
Material

Item Specification
MERCON® Multi-Purpose Automatic Transmission Fluid
XT-2-QDX (US); XT-2-LM12 (Canada)		 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-1-C or XG-1-K (US); CXG-1-C (Canada)		 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. Fig 1: Marking Countershaft In Relation To Oil Pump Slot
    GF0007347Courtesy of FORD MOTOR CO.
  2. Index-mark the countershaft in relation to the oil pump slot.
    3. Fig 2: Oil Pump Slot In Countershaft
    GF0007348Courtesy of FORD MOTOR CO.
    Fig 3: Countershaft & Mainshaft
    GF0007349Courtesy of FORD MOTOR CO.
  3. Position the countershaft to the mainshaft on the Gear Pack Assembly Fixture.
    4. Fig 4: Countershaft Rear Bearing Spacer
    GF0007350Courtesy of FORD MOTOR CO.
  4. Install the countershaft rear bearing spacer.
    • The countershaft rear bearing spacer can be installed either way.
    5. Fig 5: 1st/2nd & 3rd/4th Shift Fork & Shift Rail Assemblies
    GF0007351Courtesy of FORD MOTOR CO.
  5. Install the 1st/2nd and 3rd/4th 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.
    6. Fig 6: Interlock Plate
    GF0007352Courtesy of FORD MOTOR CO.
  6. Install the interlock plate.
    • The stamped part numbers on the interlock plate must face toward the input shaft.
    7. Fig 7: Intermediate Housing On Mainshaft, Countershaft, & Shift Rails
    GF0007353Courtesy 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.
    8. Fig 8: Interlock Plate Bolts
    GF0007354Courtesy of FORD MOTOR CO.
  8. Install the interlock plate bolts.
    • Tighten to 10 Nm (89 lb-in).
    9. Fig 9: Exploded View Of 5th Gear Synchronizer Assembly
    GF0007355Courtesy of FORD MOTOR CO.
  9. Assemble the 5th gear synchronizer assembly.
    10. Fig 10: Installing 5th Gear Synchronizer Assembly
    GF0007356Courtesy of FORD MOTOR CO.
  10. Install the 5th gear synchronizer assembly.
    • Install the 5th gear synchronizer with the snap ring on the synchronizer body facing down against the intermediate housing.
    • The 5th gear synchronizer will slide into place and does not require heat to install.
    11. Fig 11: Installing Countershaft Bushing
    GF0007357Courtesy of FORD MOTOR CO.
    CAUTION: To prevent damage, do not heat the countershaft bushing higher than 150°C (300°F) maximum.
  11. Remove the countershaft bushing from the Gear/Bearing Heater, then install the countershaft bushing.
    12. Fig 12: Countershaft Needle Bearing
    GF0007358Courtesy of FORD MOTOR CO.
    NOTE: Allow the countershaft bushing to cool for 2-4 minutes before installing the countershaft needle bearing.
  12. Install the countershaft needle bearing.
    13. Fig 13: 5th Gear
    GF0007359Courtesy of FORD MOTOR CO.
  13. Install the 5th gear.
    14. Fig 14: Snap Ring
    GF0007360Courtesy 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.
    15. Fig 15: Low Gear Thrust Washer (6.0L)
    GF0007361Courtesy of FORD MOTOR CO.
  15. For vehicles equipped with a 6.0L engine, install the low gear thrust washer.
    16. Fig 16: Mainshaft Low Gear Needle Bearings
    GF0007362Courtesy of FORD MOTOR CO.
  16. Install the 2 mainshaft low gear needle bearings.
    17. Fig 17: Low Gear
    GF0007363Courtesy of FORD MOTOR CO.
  17. Install low gear.
    18. Fig 18: Low & Reverse Synchronizer Assembly
    GF0007364Courtesy 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.
    19. Fig 19: Mainshaft Reverse Gear Bushing
    GF0007365Courtesy of FORD MOTOR CO.
    CAUTION: To prevent damage, do not heat the reverse gear bushing higher than 150°C (300°F) maximum.
  19. Remove the mainshaft reverse gear bushing from the Gear/Bearing Heater, then install the mainshaft bushing.
    20. Fig 20: Mainshaft Needle Bearing
    GF0007366Courtesy of FORD MOTOR CO.
    NOTE: Allow the mainshaft reverse gear bushing to cool for 2-4 minutes before installing mainshaft needle bearing.
  20. Install the mainshaft needle bearing.
    21. Fig 21: Reverse Gear
    GF0007367Courtesy of FORD MOTOR CO.
  21. Install the reverse gear. Pull the synchronizer sliding sleeve into the NEUTRAL position.
    22. Fig 22: Output Bearing Thrust Washer
    GF0007368Courtesy of FORD MOTOR CO.
    CAUTION: To prevent damage, do not heat the output bearing thrust washer higher than 150°C (300°F) maximum.
  22. Remove the output bearing thrust washer from the Gear/Bearing Heater, then using the special tools, install the output bearing thrust washer.
    23. Fig 23: Mainshaft Output Bearing
    GF0007369Courtesy of FORD MOTOR CO.
    CAUTION: To prevent damage, do not heat the rear mainshaft output bearing higher than 150°C (300°F) maximum.
  23. Remove the mainshaft output bearing from the Gear/Bearing Heater, then using the special tools, install the rear mainshaft output bearing.
    24. Fig 24: Checking Axial Gear Clearance At 5th Gear
    GF0007370Courtesy of FORD MOTOR CO.
  24. Using the Dial Indicator with Bracketry and the Clutch Housing Gauge, check the axial gear clearance at 5th gear.
    • If not within specifications, disassemble and reinspect.
    25. Fig 25: Checking Axial Gear Clearance At Low Gear
    GF0007371Courtesy 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.
    26. Fig 26: Checking Axial Gear Clearance At Reverse Gear
    GF0007372Courtesy 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.
    27. Fig 27: Snap Ring (4WD)
    GF0007232Courtesy of FORD MOTOR CO.
    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.
    28. Fig 28: 5th Gear Shift Fork & Shift Rail
    GF0007373Courtesy of FORD MOTOR CO.
    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 5th gear position.
  28. Install the 5th gear shift fork and the shift rail.
    29. Fig 29: Roll Pin
    GF0007374Courtesy of FORD MOTOR CO.
  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.
    30. Fig 30: Low/Reverse Gear Shift Fork & Shift Rail
    GF0007375Courtesy of FORD MOTOR CO.
    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.
  30. Install the low/reverse gear shift fork and the shift rail.
    31. Fig 31: Roll Pin
    GF0007376Courtesy of FORD MOTOR CO.
  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.
    32. Fig 32: Shift Detent Spring & Detent Plug
    GF0007377Courtesy of FORD MOTOR CO.
  32. Install the 4 shift detent springs and 4 new detent plugs.
    • Apply gasket maker to the detent plugs before installing.
    33. Fig 33: Main Shift Rail & Interlock Plate
    GF0007378Courtesy 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.
    34. Fig 34: Lower Shift Finger & Roll Pin
    GF0007379Courtesy 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.
    35. Fig 35: Main Shift Rail Driver & Roll Pin
    GF0007380Courtesy 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.
    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. Fig 36: Lifting Intermediate Housing & Gear Assembly
    GF0007220Courtesy of FORD MOTOR CO.
    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 2 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.
    38. Fig 37: Intermediate Housing To Case Bolts
    GF0007219Courtesy of FORD MOTOR CO.
  38. Install the intermediate housing-to-case bolts.
    • Tighten to 23 Nm (17 lb-ft).
    39. Fig 38: Checking Countershaft Clearance
    GF0007381Courtesy 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.
    40. Fig 39: Lifting Up On 3rd Gear Counter
    GF0007382Courtesy of FORD MOTOR CO.
    NOTE: The tool is installed on the PTO opening.
  40. Using the special tool, measure for countershaft clearance.
    • Lift up on the 3rd 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.
    41. Fig 40: Checking Mainshaft Clearance
    GF0007383Courtesy 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.
  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.
    43. Fig 41: Lifting Up On Low Gear
    GF0007384Courtesy of FORD MOTOR CO.
    Fig 42: Intermediate Housing To Case Bolts
    GF0007219Courtesy of FORD MOTOR CO.
  43. Remove the special tools, then remove the intermediate housing-to-case bolts.
    44. Fig 43: Lifting Intermediate Housing & Gear Assembly
    GF0007220Courtesy of FORD MOTOR CO.
  44. Using a suitable lifting device, a suitable chain and 2 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.
    45. Fig 44: Removing Input Shaft Bearing Cup
    GF0007311Courtesy of FORD MOTOR CO.
  45. Using the special tools, remove the input shaft bearing cup.
    46. Fig 45: Removing Countershaft Bearing Cup & Shim
    GF0007307Courtesy of FORD MOTOR CO.
  46. Using the special tools, remove the countershaft bearing cup.
    47. Fig 46: Installing Input Shaft Bearing Cup
    GF0007321Courtesy of FORD MOTOR CO.
    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.
    48. Fig 47: Installing Countershaft Bearing Cup
    GF0007385Courtesy of FORD MOTOR CO.
    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.
    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 10 minutes to tighten the 2 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. Fig 48: Lifting Intermediate Housing & Gear Assembly
    GF0007220Courtesy of FORD MOTOR CO.
    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.
    51. Fig 49: Intermediate Housing To Case Bolts
    GF0007219Courtesy of FORD MOTOR CO.
  51. Install the intermediate housing-to-case bolts.
    • Apply threadlock and sealer to the intermediate housing bolts.
    • Tighten to 23 Nm (17 lb-ft).
    52. Fig 50: Extension Housing To Intermediate Housing
    GF0007386Courtesy of FORD MOTOR CO.
    CAUTION: Do not use a silicone sealing compound.
    NOTE: Do not wait longer than 10 minutes to tighten the bolts due to the rapid cure time of the sealant.
  52. Thinly coat the rear sealing surface of the intermediate housing and the extension housing with gasket maker. Install the extension housing and the 19 extension housing bolts.
    • Tighten to 23 Nm (17 lb-ft).
    53. Fig 51: Main Shift Detent
    GF0007387Courtesy of FORD MOTOR CO.
  53. Apply threadlock and sealer to the threads of the main shift detent. Install the detent plunger and the main shift detent.
    • Tighten to 65 Nm (48 lb-ft).
    54. Fig 52: PTO Cover Bolts
    GF0007388Courtesy of FORD MOTOR CO.
    NOTE: Cross tighten the bolts.
  54. Apply threadlock and sealer to the threads of the PTO cover bolts. Install a new gasket and the PTO cover.
    • Tighten to 38 Nm (28 lb-ft).
    55. Fig 53: Installing Input Oil Seal
    GF0007389Courtesy of FORD MOTOR CO.
    NOTE: The tool listed is for gasoline equipped vehicles only. To install the seal for diesel equipped vehicles, use a suitable 1.75 inch ID x 10 inch pipe. Make sure the seal is flush with the transmission case.
  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®.
    56. Fig 54: Guide Tube Bolts
    GF0007390Courtesy of FORD MOTOR CO.
  56. Apply threadlock and sealer to the threads of the guide tube bolts. Install the guide tube.
    • Tighten bolts to 23 Nm (17 lb-ft).
    57. Fig 55: Clutch Release Lever And Clutch Release Hub & Bearing
    GF0007212Courtesy 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.
    58. Fig 56: Installing Output Oil Seal (RWD)
    GF0007175Courtesy 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.
    59. Fig 57: Installing Output Oil Seal (4WD)
    GF0007391Courtesy of FORD MOTOR CO.
    Fig 58: Transmission Flange & Pinion Flange Lock Nut
    GF0007392Courtesy of FORD MOTOR CO.
    NOTE: This step is for 2-wheel drive vehicles only.
  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.
    • Tighten to 330 Nm (244 lb-ft).
  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 N.m.
  62. Remove the shifter for installation.
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