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Home >> Ford >> 2002 >> Escape 3.0 1, FWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1848 (Manual Transmission - ZF S6-650 & M6HD - 6-Speed -- F250-F550 Super Duty (2007)) >> Disassembly >> Transmission >> All vehicles

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WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2007 Ford Pickup, 2007 Ford F550 Super Duty, 2007 Ford F450 Super Duty, 2007 Ford Cab & Chassis, and 2006 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
    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. Fig 1: Clutch Release Lever And Clutch Release Hub & Bearing
    GF0007212Courtesy of FORD MOTOR CO.
  3. Remove the clutch release lever and the clutch release hub and bearing.
    4. Fig 2: Setting Transmission On End
    GF0007213Courtesy 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.
  4. Position the transmission on the floor with the output flange pointing upward.


Fig 1: Extension Housing Bolts
GF0007214Courtesy of FORD MOTOR CO.
  1. Remove the 19 bolts.
    2. Fig 2: Removing Detent Plugs
    GF0007215Courtesy of FORD MOTOR CO.
    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.
  2. 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.
    3. Fig 3: Main Shift Detent
    GF0007216Courtesy of FORD MOTOR CO.
  3. Remove the main shift detent.
    4. Fig 4: Main Shift Detent & Detent Plunger
    GF0007217Courtesy of FORD MOTOR CO.
  4. Separate the main shift detent from the detent plunger.
    • Inspect the detent plunger for wear or damage. Install a new dent plunger as necessary.
    5. Fig 5: Extension Housing
    GF0007218Courtesy of FORD MOTOR CO.
  5. Remove the extension housing from the intermediate housing.
    • Using a soft-faced hammer, tap the extension housing lightly to break the gasket seal.
    6. Fig 6: Intermediate Housing To Case Bolts
    GF0007219Courtesy of FORD MOTOR CO.
  6. Remove the intermediate housing to case bolts.
    7. Fig 7: Lifting Intermediate Housing & Gear Assembly
    GF0007220Courtesy of FORD MOTOR CO.
  7. Using a suitable lifting device, a suitable chain and 2 S-hooks, lift the intermediate housing and gear assembly out of the main case.
    • Place the S-hooks in the intermediate housing where the 2 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.
    8. Fig 8: Covering Chains
    GF0007221Courtesy of FORD MOTOR CO.
    Fig 9: Intermediate Housing & Gear Assembly On Special Tool
    GF0007222Courtesy of FORD MOTOR CO.
  8. Position the intermediate housing and gear assembly on the special tool.
    • Securely fasten the holding plate to a sturdy work bench.
    9. Fig 10: Low/Reverse/5th Gear Main Shift Rail Driver & Pin
    GF0007223Courtesy of FORD MOTOR CO.
  9. Remove the low/reverse/5th gear main shift rail driver.
    1. Remove the 2 roll pins.
      • Use a hammer and punch or an air hammer and roll pin remover.
    • Remove the main shift rail driver.
    10. Fig 11: 1st/2nd And 3rd/4th Rail Driver & Pin
    GF0007224Courtesy of FORD MOTOR CO.
    NOTE: The shift finger is also the 1st/2nd and 3rd/4th rail driver.
  10. 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.
    11. Fig 12: Roll Pin
    GF0007225Courtesy of FORD MOTOR CO.
    Fig 13: Lower Shift Finger And The Main Shift Rail
    GF0007226Courtesy of FORD MOTOR CO.
  11. Remove the lower shift finger and the main shift rail.
    • Remove the lower shift finger.
      • Rotate the rail driver counterclockwise and pull outward to remove.
    • Remove the main shift rail.
    12. Fig 14: 5th Gear Shift Fork Roll Pins
    GF0007227Courtesy of FORD MOTOR CO.
  12. Align the interlock plate into 2nd gear position, engage 2nd gear, then remove the two 5th gear shift fork roll pins.
    • Use a hammer and punch or an air hammer and roll pin remover to remove.
    13. Fig 15: 5th Gear Shift Fork And Shift Rail
    GF0007228Courtesy of FORD MOTOR CO.
  13. Remove the 5th gear shift fork and shift rail.
    • Align the interlock plate into the 5th gear position. Remove the shift rail by tapping the shift fork with a soft-faced hammer while pulling up on the shift rail.
    14. Fig 16: Low And Reverse Gear Shift Fork Roll Pin
    GF0007229Courtesy of FORD MOTOR CO.
  14. 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.
    15. Fig 17: Low/Reverse Gear Shift Fork And Shift Rail
    GF0007230Courtesy of FORD MOTOR CO.
  15. 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.
    16. Fig 18: Shift Rail Detent
    GF0007231Courtesy of FORD MOTOR CO.
  16. 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.
    17. Fig 19: Snap Ring
    GF0007232Courtesy of FORD MOTOR CO.
  17. On 4-wheel drive vehicles, remove and discard the snap ring.
    18. Fig 20: Removing Mainshaft Rear Bearing, Output Bearing Thrust Washer, Mainshaft Low Gear, Mainshaft Low Gear Bushing, Synchronizer Assembly (Low And Reverse) & Mainshaft Reverse Gear
    GF0007233Courtesy of FORD MOTOR CO.
  18. 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.
    19. Fig 21: Removing Mainshaft Rear Bearing & Output Bearing Thrust Washer From Low And Reverse Assembly
    GF0007234Courtesy of FORD MOTOR CO.
  19. 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.
    20. Fig 22: Removing Mainshaft Needle Bearings
    GF0007235Courtesy of FORD MOTOR CO.
  20. Remove the mainshaft needle bearings.
    • Inspect the bearings for wear or damage. Install new bearings as necessary.
    21. Fig 23: Removing Low Gear
    GF0007236Courtesy of FORD MOTOR CO.
  21. 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.
    22. Fig 24: Exploded View Of Synchronizer Assembly
    GF0007237Courtesy of FORD MOTOR CO.
  22. 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.
    23. Fig 25: Checking Synchronizer Ring & Gear Clearance (With Specifications)
    GF0007238Courtesy of FORD MOTOR CO.
  23. Check the clearance between the synchronizer ring and the gear.
    • Place the synchronizer ring onto the synchronizer sliding sleeve. Position the synchronizer ring on the gear.
    • 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.
    24. Fig 26: Mainshaft Needle Bearing
    GF0007239Courtesy of FORD MOTOR CO.
  24. Remove the mainshaft needle bearing.
    25. Fig 27: Low Gear Thrust Washer (6.0L)
    GF0007240Courtesy of FORD MOTOR CO.
  25. For vehicles equipped with a 6.0L engine, remove the low gear thrust washer.
    26. Fig 28: Snap Ring
    GF0007241Courtesy of FORD MOTOR CO.
  26. Remove and discard the snap ring.
    27. Fig 29: Countershaft Rear Thrust Washer
    GF0007242Courtesy of FORD MOTOR CO.
  27. Remove the countershaft rear thrust washer.
    28. Fig 30: 5th Gear
    GF0007243Courtesy of FORD MOTOR CO.
  28. Remove 5th gear.
    29. Fig 31: Countershaft Needle Bearing
    GF0007244Courtesy of FORD MOTOR CO.
  29. Remove the countershaft needle bearing.
    30. Fig 32: Interlock Plate Bolts
    GF0007245Courtesy of FORD MOTOR CO.
  30. Remove the interlock plate bolts.
    31. Fig 33: Removing Countershaft Bushing, Countershaft 5Th Gear Synchronizer Assembly & Intermediate Housing
    GF0007246Courtesy of FORD MOTOR CO.
    NOTE: Do not use power tools to remove.
    NOTE: Make sure the shift rails are not binding while pulling up on the intermediate housing.
  31. Using the special tools, remove the countershaft bushing, the countershaft 5th gear synchronizer assembly and the intermediate housing.
    • When installing the Centerplate Legs, position them opposing one another.
    • Inspect the countershaft 5th gear synchronizer, countershaft bushing and the intermediate plate for wear or damage. Install new components as necessary.
    32. Fig 34: Exploded View Of Synchronizer Assembly
    GF0007237Courtesy of FORD MOTOR CO.
  32. Disassemble the countershaft 5th 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.
    33. Fig 35: Checking Synchronizer Ring & Gear Clearance (With Specifications)
    GF0007238Courtesy of FORD MOTOR CO.
  33. Check the clearance between the synchronizer ring and the gear.
    • Place the synchronizer ring onto the synchronizer sliding sleeve. Position the synchronizer ring on the gear.
    • 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 5th gear, install a new synchronizer assembly or 5th gear to obtain correct specification.
    34. 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.
  34. 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.
    35. Fig 36: 1st/2nd & 3rd/4th Shift Fork & Shift Rail Assemblies
    GF0007247Courtesy of FORD MOTOR CO.
  35. Remove the interlock plate, the 1st/2nd and 3rd/4th shift fork and shift rail assemblies.
    36. Fig 37: Checking Shift Fork Pads & Centers
    GF0007248Courtesy of FORD MOTOR CO.
  36. Inspect all the shift fork pads and centers for wear or damage. Install new shift forks as necessary.
    37. CAUTION: To prevent damage, do not heat the bearings higher than 150°C (300°F) maximum.
  37. 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.
    38. Fig 38: Countershaft Rear Bearing Spacer
    GF0007249Courtesy of FORD MOTOR CO.
  38. Remove the countershaft rear bearing spacer.
    39. Fig 39: Countershaft
    GF0007250Courtesy of FORD MOTOR CO.
  39. Remove the countershaft from the Gear Pack Assembly Fixture and set it aside.
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