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Section 459 (Manual Transmission - F250-F550): Assembly: Transmission

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SPECIAL TOOLS CHART

G04650618
 Gear/Bearing Heater
164-R3900
G04650619
 Heat Gun
107-R0300 or equivalent
G04650620
 Fixture, Gear Pack
308-381
G04650621
 Remover, Bearing Cup
308-047 (T77F-1102-A)
G04650622
 Installer, Countershaft Front Bearing Cup
308-390
G04650623
 Handle
205-D055 (D81L-4000-A)
G04650624
 Installer, Input Shaft Bearing Cup
308-391
G04650625
 Remover, Input Shaft Bearing Cup
308-S392
G04650626
 Remover/Installer, Thrust Washer Bearing Cup
308-416
G04650627
 Installer, Output Shaft Oil Seal (Four Wheel Drive [4WD])
308-383
G04650628
 Installer, Output Shaft Oil Seal (Rear Wheel Drive [RWD])
308-382
G04650629
 Installer, Input Shaft Oil Seal
308-379 (Gas engines only)
G04650630
 Holding Fixture, Drive Pinion Flange
205-126 (T78P-4851-A)
G04650631
 Socket, Mainshaft Locknut (36mm)
308-127 (T87T-7025-AH)
G04650632
 Dial Indicator Gauge with Holding Fixture
100-002 (TOOL-4201-C)
G04650633
 Gauge, Clutch Housing
308-021 (T75L-4201-A)
MATERIAL CHART

Item Specification
MERCON® Multi-Purpose Automatic Transmission Fluid 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-l-C 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. Index-mark the countershaft in relation to the oil pump slot.
    Fig 1: Locating Index-Mark On Countershaft (1 Of 2)
    G04650634Courtesy of FORD MOTOR CO.
    Fig 2: Locating Index-Mark On Countershaft (2 Of 2)
    G04650635Courtesy of FORD MOTOR CO.
  3. Position the countershaft to the mainshaft on the Gear Pack Assembly Fixture.
    Fig 3: Identifying Countershaft And Mainshaft
    G04650636Courtesy of FORD MOTOR CO.
  4. Install the countershaft rear bearing spacer.
    • The countershaft rear bearing spacer can be installed either way.
      Fig 4: Installing Countershaft Rear Bearing Spacer
      G04650637Courtesy 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.
      Fig 5: Locating 1st/2nd And 3rd/4th Shift Fork
      G04650638Courtesy of FORD MOTOR CO.
  6. Install the interlock plate.
    • The stamped part numbers on the interlock plate must face toward the input shaft.
      Fig 6: Installing Interlock Plate
      G04650639Courtesy 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.
      Fig 7: Locating Intermediate Housing On Mainshaft
      G04650640Courtesy of FORD MOTOR CO.
  8. Install the interlock plate bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 8: Locating Interlock Plate Bolts
      G04650641Courtesy of FORD MOTOR CO.
  9. Assemble the 5th gear synchronizer assembly.
    Fig 9: Exploded View Of 5th Gear Synchronizer Assembly
    G04650642Courtesy 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.
      Fig 10: Installing 5th Gear Synchronizer With Snap Ring
      G04650643Courtesy of FORD MOTOR CO.
    11. CAUTION: To prevent damage, do not heat the countershaft bushing higher than 150°C (300°F) maximum.
    Fig 11: Locating Countershaft Bushing
    G04650644Courtesy of FORD MOTOR CO.
  11. Remove the countershaft bushing from the Gear/Bearing Heater, then install the countershaft bushing.
    12. NOTE: Allow the countershaft bushing to cool for 2-4 minutes before installing the countershaft needle bearing.
    Fig 12: Installing Countershaft Needle Bearing
    G04650645Courtesy of FORD MOTOR CO.
  12. Install the countershaft needle bearing.
  13. Install the 5th gear.
    Fig 13: Locating 5th Gear
    G04650646Courtesy 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.
      Fig 14: Locating Snap Ring
      G04650647Courtesy of FORD MOTOR CO.
  15. For vehicles equipped with a 6.0L engine, install the low gear thrust washer.
    Fig 15: Locating Low Gear Thrust Washer
    G04650648Courtesy of FORD MOTOR CO.
  16. Install the 2 mainshaft low gear needle bearings.
    Fig 16: Locating Mainshaft Low Gear Needle Bearings
    G04650649Courtesy of FORD MOTOR CO.
  17. Install low gear.
    Fig 17: Locating Low Gear
    G04650650Courtesy 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.
      Fig 18: Locating Low/Reverse Synchronizer
      G04650651Courtesy of FORD MOTOR CO.
    19. CAUTION: To prevent damage, do not heat the reverse gear bushing higher than 150°C (300°F) maximum.
    Fig 19: Installing Mainshaft Bushing
    G04650652Courtesy of FORD MOTOR CO.
  19. Remove the mainshaft reverse gear bushing from the Gear/Bearing Heater, then install the mainshaft bushing.
    20. NOTE: Allow the mainshaft reverse gear bushing to cool for 2-4 minutes before installing mainshaft needle bearing.
    Fig 20: Locating Mainshaft Needle Bearing
    G04650653Courtesy of FORD MOTOR CO.
  20. Install the mainshaft needle bearing.
  21. Install the reverse gear. Pull the synchronizer sliding sleeve into the NEUTRAL position.
    Fig 21: Locating Reverse Gear
    G04650654Courtesy of FORD MOTOR CO.
    22. CAUTION: To prevent damage, do not heat the output bearing thrust washer higher than 150°C (300°F) maximum.
    Fig 22: Locating Output Bearing Thrust Washer
    G04650655Courtesy of FORD MOTOR CO.
  22. Remove the output bearing thrust washer from the Gear/Bearing Heater, then using the special tools, install the output bearing thrust washer.
    23. CAUTION: To prevent damage, do not heat the rear mainshaft output bearing higher than 150°C (300°F) maximum.
    Fig 23: Locating Mainshaft Output Bearing
    G04650656Courtesy of FORD MOTOR CO.
  23. Remove the mainshaft output bearing from the Gear/Bearing Heater, then using the special tools, install the rear mainshaft output bearing.
  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.
      Fig 24: Checking Axial Gear Clearance
      G04650657Courtesy 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.
      Fig 25: Checking Axial Gear Clearance
      G04650658Courtesy 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.
      Fig 26: Checking Axial Gear Clearance
      G04650659Courtesy of FORD MOTOR CO.
    27. 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.
      Fig 27: Locating Snap Ring
      G04650660Courtesy of FORD MOTOR CO.
    28. 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.
    Fig 28: Locating 5th Gear Shift Fork And Shift Rail
    G04650661Courtesy of FORD MOTOR CO.
  28. Install the 5th gear shift fork and the shift rail.
  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.
      Fig 29: Locating Slot Of Roll Pin
      G04650662Courtesy of FORD MOTOR CO.
    30. 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.
    Fig 30: Locating Low/Reverse Gear Shift Fork
    G04650663Courtesy of FORD MOTOR CO.
  30. Install the low/reverse gear shift fork and the shift rail.
  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.
      Fig 31: Locating Slot Of Roll Pin
      G04650664Courtesy 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.
      Fig 32: Locating Shift Detent Springs And Detent Plugs
      G04650665Courtesy 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.
      Fig 33: Locating Main Shift Rail
      G04650666Courtesy 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.
      Fig 34: Locating Small Roll Pin
      G04650667Courtesy 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.
      Fig 35: Locating Small And Large Roll Pin
      G04650668Courtesy of FORD MOTOR CO.
    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. 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.
      Fig 36: Locating Transmission Assembly
      G04650669Courtesy of FORD MOTOR CO.
  38. Install the intermediate housing-to-case bolts.
    • Tighten to 23 Nm (17 lb-ft).
      Fig 37: Locating Intermediate Housing-To-Case Bolts
      G04650670Courtesy 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.
      Fig 38: Checking Countershaft Clearance
      G04650671Courtesy of FORD MOTOR CO.
    40. 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.
      Fig 39: Lifting Up On 3rd Gear Counter
      G04650672Courtesy 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.
      Fig 40: Checking Mainshaft Clearance
      G04650673Courtesy of FORD MOTOR CO.
  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.
      Fig 41: Checking Mainshaft Clearance
      G04650674Courtesy of FORD MOTOR CO.
  43. Remove the special tools, then remove the intermediate housing-to-case bolts.
    Fig 42: Locating Intermediate Housing-To-Case Bolts
    G04650675Courtesy 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.
      Fig 43: Locating Intermediate Housing And Gear Assembly
      G04650676Courtesy of FORD MOTOR CO.
  45. Using the special tools, remove the input shaft bearing cup.
    Fig 44: Removing Input Shaft Bearing Cup
    G04650677Courtesy of FORD MOTOR CO.
  46. Using the special tools, remove the countershaft bearing cup.
    Fig 45: Removing Countershaft Bearing Cup
    G04650678Courtesy of FORD MOTOR CO.
    47. 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.
      Fig 46: Installing Input Shaft Oil Dam Bearing Ring
      G04650679Courtesy of FORD MOTOR CO.
    48. 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.
      Fig 47: Installing Countershaft Bearing Cup
      G04650680Courtesy of FORD MOTOR CO.
    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. 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.
      Fig 48: Locating Intermediate Housing And Gear Assembly
      G04650681Courtesy 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).
      Fig 49: Locating Intermediate Housing-To-Case Bolts
      G04650682Courtesy of FORD MOTOR CO.
    52. 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).
      Fig 50: Installing Extension Housing
      G04650683Courtesy 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).
      Fig 51: Locating Detent Plunger
      G04650684Courtesy of FORD MOTOR CO.
    54. 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).
      Fig 52: Locating PTO Cover Bolts
      G04650685Courtesy of FORD MOTOR CO.
    55. 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®.
      Fig 53: Installing Input Oil Seal
      G04650686Courtesy 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).
      Fig 54: Locating Guide Tube Bolts
      G04650687Courtesy 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.
      Fig 55: Locating Release Lever And Clutch Release Hub
      G04650688Courtesy 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.
    Fig 56: Installing Output Oil Seal (1 Of 2)
    G04650689Courtesy of FORD MOTOR CO.
    Fig 57: Installing Output Oil Seal (2 Of 2)
    G04650690Courtesy of FORD MOTOR CO.
    59. 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).
      Fig 58: Tightening Pinion Flange Lock Nut
      G04650691Courtesy of FORD MOTOR CO.
  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 Nm.
  62. Remove the shifter for installation.
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