Transmission Case: Assembly

All vehicles 

1. Clean and inspect the transmission case for damage or excessive wear. Inspect the bearing, bushing and splined surfaces for damage. Install new components as necessary.

   Vehicles equipped with a PTO 

2. Clean the PTO  cover. Install the PTO  gasket and cover. Install the 6 new PTO  cover bolts.
   • Tighten to 25 Nm (18 lb-ft).
   Fig 1: Locating PTO Cover Bolts

   Courtesy of FORD MOTOR CO.

   All vehicles 

NOTE: The bearings must be installed in the transmission case by pressing on the thicker (marked) side of the bearing. When installing the bearing on the Rear Bearing Remover/Installer (307-648/3 and 307-648/4), make sure that the thicker (marked) side of the bearing faces the step on the Rear Bearing Remover/Installer (307-648/3 and 307-648/4). Failure to press on the thicker (marked) side can result in damage to the bearing.
NOTE: 307-648/4 shown in the illustration, 307-648/3 similar.
Fig 2: Locating Thicker (Marked) Side Of Bearing
Courtesy of FORD MOTOR CO.
3. Install new bearings on the Rear Bearing Remover/Installer with the thicker (marked) side of the bearing facing the step on the Rear Bearing Remover/Installer.
   1. Thicker (marked) side of the bearing
   2. Markings
   3. Thinner (unmarked) side of the bearing
   4. Rear Bearing Installer step
NOTE: The Rear Bearing Remover/Installer 307-648/3 is used to install the inside bearing and the Rear Bearing Remover/Installer 307-648/4 is used to install the outside bearing. If the Rear Bearing Remover/Installer 307-648/3 and Rear Bearing Remover/Installer 307-648/4 are not used on the correct bearings, damage to the transmission can occur.
Fig 3: Installing Inner And Outer Output Shaft Bearing
Courtesy of FORD MOTOR CO.
4. Install new bearings on the Rear Bearing Remover/Installer with the thicker (marked) side of the bearing facing the Rear Bearing Remover/Installer. Using the Rear Bearing Remover/Installer and the Forcing Screw, install the inner and outer output shaft bearing.
5. Position the park pawl and install the park pawl pin.
   Fig 4: Locating Park Pawl And Pin

   Courtesy of FORD MOTOR CO.
6. Lubricate the O-ring seal with clean transmission fluid and install the park pawl pin plug.
   • Tighten to 35 Nm (26 lb-ft).
   Fig 5: Locating Park Pawl Pin Plug

   Courtesy of FORD MOTOR CO.
7. Install the TR  sensor detent spring and loosely install the bolt.
   Fig 6: Locating TR Sensor Detent Spring

   Courtesy of FORD MOTOR CO.
8. Push the park pawl down and install the park pawl actuator rod on the park pawl. Align the TR  sensor with the detent spring pin and position the TR  sensor in place.
   1. Park pawl actuator rod
   2. Park pawl
   3. TR 
   4. Detent spring bolt
   Fig 7: Identifying Park Pawl And Actuator Rod

   Courtesy of FORD MOTOR CO.
9. Install the manual shaft in the TR  sensor and align the roll pin hole.
   1. Manual shaft
   2. TR  sensor
   3. Roll pin hole
   Fig 8: Installing Manual Shaft By Using Required Tools

   Courtesy of FORD MOTOR CO.
10. Using a suitable tool, install a new manual shaft-to- TR  sensor roll pin.
    Fig 9: Locating Manual Shaft-To-TR Sensor Roll Pin

    Courtesy of FORD MOTOR CO.
11. Tighten the TR  sensor detent spring bolt.
    • Tighten to 12 Nm (106 lb-in).
    Fig 10: Locating TR Sensor Detent Spring Bolt

    Courtesy of FORD MOTOR CO.