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Section 86 (Manual Transmission - Tr3650): Disassembly: Transmission: Disassembly

WARNING: This page is about a different car, the 2009 Ford Mustang. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: If any roll pins, retaining rings or bearings are removed during disassembly, install new components. Install bearings and bearing cups as a set.
NOTE: For additional information, refer to the exploded view under the ASSEMBLY .
  1. Clean the transmission exterior with solvent and dry with compressed air. During disassembly, clean all components with solvent and dry with compressed air.
  2. Attach the transmission to the special tool.
    3. Fig 1: Identifying Special Tool 307-003
    GF0015812Courtesy of FORD MOTOR CO.
  3. Remove the output flange nut, washer and oil seal.
    4. Fig 2: Locating Output Flange Nut, Washer And Oil Seal
    GF0015813Courtesy of FORD MOTOR CO.
  4. Using the special tool, remove the output flange.
    5. Fig 3: Identifying Special Tool 205-D070
    GF0015814Courtesy of FORD MOTOR CO.
    NOTE: Position a drain pan under the transmission.
  5. Remove the drain plug, then rotate the transmission to a horizontal position and drain the fluid.
    6. Fig 4: Locating Case Plug
    GF0015815Courtesy of FORD MOTOR CO.
  6. Using the special tool, remove the extension housing fluid seal.
    7. Fig 5: Identifying Special Tool 307-001
    GF0015816Courtesy of FORD MOTOR CO.
  7. Remove the output shaft speed (OSS) sensor bolt and the OSS sensor.
    8. Fig 6: Locating Output Shaft Speed (OSS) Sensor
    GF0015817Courtesy of FORD MOTOR CO.
  8. Remove the 12 extension housing bolts.
    9. Fig 7: Locating Transmission Bolt
    GF0015818Courtesy of FORD MOTOR CO.
  9. Using a flat-blade screwdriver, separate the extension housing, then remove the gearshift offset lever from the transmission case, then remove the extension housing.
    • Remove and discard the split pin from the gearshift offset lever during removal.
    10. Fig 8: Separating Extension Housing Using Screwdriver
    GF0015819Courtesy of FORD MOTOR CO.
  10. Remove the 5th/reverse gear lockout bolt.
    11. Fig 9: Locating Gear Lockout Bolt
    GF0015820Courtesy of FORD MOTOR CO.
  11. Remove the snap ring.
    12. Fig 10: Locating Snap Ring
    GF0001096Courtesy of FORD MOTOR CO.
    NOTE: Always install a new bearing race if installing a new bearing.
  12. Remove the output shaft bearing.
    • Inspect the bearing, install a new bearing if necessary.
    13. Fig 11: Locating Output Shaft Bearing
    GF0015821Courtesy of FORD MOTOR CO.
  13. Using the special tools, remove the output shaft bearing race.
    14. Fig 12: Removing Output Shaft Bearing Race Using Special Tools
    GF0046448Courtesy of FORD MOTOR CO.
  14. Remove the bearing race spacer.
  15. Remove the OSS sensor tone wheel retaining ring.
    16. Fig 13: Locating OSS Sensor Tone Wheel Retaining Ring
    GF0015823Courtesy of FORD MOTOR CO.
  16. Using the special tools, remove the OSS sensor tone wheel.
    17. Fig 14: Removing OSS Sensor Tone Wheel Using Special Tools
    GF0046449Courtesy of FORD MOTOR CO.
  17. Remove the OSS sensor tone wheel check ball.
    18. Fig 15: Locating OSS Sensor Tone Wheel Check Ball
    GF0015825Courtesy of FORD MOTOR CO.
  18. Remove and discard the 5th gear synchronizer retaining ring.
    19. Fig 16: Locating Retaining Ring
    GF0015826Courtesy of FORD MOTOR CO.
  19. Using a 5/32-inch drift and a hammer, remove and discard the pin from the 5th gear shift fork.
    20. Fig 17: Locating Pin From 5th Gear Shift Fork
    GF0015827Courtesy of FORD MOTOR CO.
    NOTE: A flat-blade screwdriver may aid in removal.
  20. Using the special tool, remove the 5th gear shift fork, synchronizer assembly, synchronizer cone and the 5th gear as an assembly.
    21. Fig 18: Identifying Special Tool 205-D072
    GF0015828Courtesy of FORD MOTOR CO.
  21. Remove the 5th gear clutch cone.
    22. Fig 19: Locating 5th Gear Clutch Cone
    GF0015829Courtesy of FORD MOTOR CO.
  22. Remove the 5th gear synchronizer blocking ring.
    • Inspect the blocking ring for wear or damage. Install new blocking rings as necessary.
    23. Fig 20: Locating 5th Gear Synchronizer Blocking Ring
    GF0015830Courtesy of FORD MOTOR CO.
  23. Remove the 5th gear synchronizer sleeve from the synchronizer hub.
    24. Fig 21: Locating Gear Synchronizer Sleeve From Synchronizer Hub
    GF0015831Courtesy of FORD MOTOR CO.
  24. Remove the synchronizer inserts and the springs.
    25. Fig 22: Locating Synchronizer Inserts And Springs
    GF0015832Courtesy of FORD MOTOR CO.
  25. Remove the 5th gear needle bearings and the thrust washer.
    • Inspect the needle bearings for wear or damage. Install new bearings as necessary.
    26. Fig 23: Locating 5th Gear Needle Bearings And Thrust Washer
    GF0015833Courtesy of FORD MOTOR CO.
  26. Remove the check ball.
    27. Fig 24: Locating Check Ball
    GF0015834Courtesy of FORD MOTOR CO.
  27. Using a 5/32-inch drift and a hammer, drive out the split pin, then remove the 5th/reverse lever fork. Discard the split pin.
    28. Fig 25: Locating 5th/Reverse Lever Fork
    GF0015835Courtesy of FORD MOTOR CO.
  28. Remove the main shift rail and the 2 plastic spacers.
    29. Fig 26: Locating Main Shift Rail
    GF0015836Courtesy of FORD MOTOR CO.
  29. Remove and discard the 2 plastic spacers.
    30. Fig 27: Removing Plastic Spacers
    GF0015837Courtesy of FORD MOTOR CO.
  30. Using a 5/32-inch drift and a hammer, drive out the split pin, then remove the 3rd/4th shift finger. Discard the split pin.
    31. Fig 28: Locating Split Pin
    GF0015838Courtesy of FORD MOTOR CO.
  31. Using a 5/32-inch drift and a hammer, drive out the split pin, then remove the 1st/2nd shift finger. Discard the split pin.
    32. Fig 29: Identifying Split Pin
    GF0015839Courtesy of FORD MOTOR CO.
  32. Remove the shift interlock plate bolts and the shift interlock plate.
    33. Fig 30: Locating Shift Interlock Plate And Bolts
    GF0015840Courtesy of FORD MOTOR CO.
  33. Using a magnet, remove the interlock pins.
    • One lock pin in the center rail, 2 between the rails.
    34. Fig 31: Locating Interlock Pins
    GF0015841Courtesy of FORD MOTOR CO.
  34. Remove the 5th/reverse gear lockout side bolt.
    35. Fig 32: Locating 5th/Reverse Gear Lockout Side Bolt
    GF0015842Courtesy of FORD MOTOR CO.
  35. Remove the 5th/reverse gear lockout top bolt, then remove the seal, arm and spring.
    36. Fig 33: Locating 5th/Reverse Gear Lockout Spring, Arm, Seal And Top Bolt
    GF0015843Courtesy of FORD MOTOR CO.
    NOTE: Do not remove all the bolts while in the horizontal position.
  36. Remove the clutch housing-to-transmission main case bolts.
    • Rotate the transmission to a horizontal position. Remove 12 bolts, leaving 2 opposing bolts in. Rotate the transmission to a vertical position, then remove the remaining 2 bolts.
    37. Fig 34: Locating Clutch Housing-To-Main Case Bolts
    GF0015844Courtesy of FORD MOTOR CO.
  37. Carefully pry the clutch housing from the transmission main case.
    38. Fig 35: Locating Clutch Housing From Transmission Main Case
    GF0015845Courtesy of FORD MOTOR CO.
  38. Remove the transmission main case from the clutch housing.
    • The countershaft bearing will remain in the housing. Lightly tap the bearing to remove.
    • Inspect the bearing and install a new one if necessary.
    39. Fig 36: Removing Transmission Main Case From Clutch Housing
    GF0015846Courtesy of FORD MOTOR CO.
  39. Remove the 3 detent plugs.
    40. Fig 37: Locating Detent Plugs
    GF0015847Courtesy of FORD MOTOR CO.
  40. Remove the 3 detent springs.
  41. Remove the 3 detents.
    42. Fig 38: Locating Detent Springs
    GF0015848Courtesy of FORD MOTOR CO.
  42. Using a jack and a block of wood, lift the mainshaft 13 mm (0.50 in) upward, then tilt the countershaft outward and remove the countershaft.
    43. Fig 39: Locating Countershaft
    GF0015849Courtesy of FORD MOTOR CO.
  43. While holding the mainshaft, release the jack and remove the mainshaft and shift assembly.
    44. Fig 40: Removing Mainshaft And Shift Assembly
    GF0015850Courtesy of FORD MOTOR CO.
  44. Remove the input shaft. For input shaft disassembly, refer to Input Shaft and Bearing .
    45. Fig 41: Locating Input Shaft
    GF0015851Courtesy of FORD MOTOR CO.
  45. Carefully remove the shift rails and shift forks from the main shaft. For gearshift rail and fork disassembly, refer to Gearshift Rail and Fork .
    46. Fig 42: Locating Shift Rails And Shift Forks On Mainshaft
    GF0015852Courtesy of FORD MOTOR CO.
  46. Remove the reverse idler shaft bolt. Remove and discard the seal.
    47. Fig 43: Locating Reverse Idler Shaft Bolt
    GF0015853Courtesy of FORD MOTOR CO.
  47. Remove the reverse idler gear assembly.
  48. Remove the reverse idler gear from the shaft.
    • Inspect the gear for wear or damage. Install a new gear as necessary.
    49. Fig 44: Locating Reverse Idler Gear On Shaft
    GF0015854Courtesy of FORD MOTOR CO.
  49. Remove the reverse idler gear bearing.
    • Inspect the bearing for wear or damage. Install new bearings as necessary.
    50. Fig 45: Locating Reverse Idler Gear Bearing
    GF0015855Courtesy of FORD MOTOR CO.
  50. Release the clip and remove the clutch slave cylinder connector.
  51. Remove the clutch slave cylinder. For additional information, refer to CLUTCH CONTROLS .
    52. Fig 46: Locating Clutch Slave Cylinder
    GF0015856Courtesy of FORD MOTOR CO.
  52. Remove and discard the plastic retainer.
    53. Fig 47: Locating Plastic Retainer
    GF0015857Courtesy of FORD MOTOR CO.
  53. Disassemble the clutch housing.
    1. Remove the countershaft bearing cup and shim.
    2. Remove the input shaft bearing cup and shim.
    3. Remove the input shaft seal.
      • Carefully pry out from the inside of the case.
    54. Fig 48: Identifying Input Shaft Seal
    GF0015858Courtesy of FORD MOTOR CO.
  54. Remove the rear countershaft bearing.
    • Inspect the bearing for wear or damage. Install new bearings as necessary.
    55. Fig 49: Locating Rear Countershaft Bearing
    GF0015859Courtesy of FORD MOTOR CO.
  55. Remove the rear countershaft bearing cup and the rear output shaft bearing cup.
    • Inspect the bearing and bearing cup for wear or damage. Install new components as necessary.
    56. Fig 50: Locating Rear Countershaft Bearing Cup And Rear Output Shaft Bearing Cup
    GF0015860Courtesy of FORD MOTOR CO.
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