LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2009 >> Flex Limited, FWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1488 (Manual Transmission - T5OD) >> Assembly >> Transmission

Section 1488 (Manual Transmission - T5OD): Assembly: Transmission

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.
Special Tools

Illustration Tool Name Tool Number
GF0001072Courtesy of FORD MOTOR CO.
 Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent
GF0000771Courtesy of FORD MOTOR CO.
 Gauge, Clutch Housing 308-021 (T75L-4201-A)
GF0001074Courtesy of FORD MOTOR CO.
 Installer, Torrington Bearing 308-083 (T83P-7025-AH)
GF0001073Courtesy of FORD MOTOR CO.
 Installer, Transmission Extension Housing Oil Seal 308-227 (T94P-7657-A)
GF0001069Courtesy of FORD MOTOR CO.
 Remover/Installer, Bearing Tube 308-052 (T77J-7025-B)
Material

Item Specification
Clear Silicone Rubber
TA-32		 ESB-M4G92-A
MERCON® V Automatic Transmission Fluid
XT-5-QM (or XT-5-QMC) (US); CXT-5-LM12 (Canada)		 MERCON® V
Multi-Purpose Grease
XG-4 and/or XL-5		 ESB-M1C93-B
Premium Long-Life Grease
XG-1-C or XG-1-K (US); CXG-1-C (Canada)		 ESA-M1C75-B
Thread Sealant with PTFE
TA-24		 WSK-M2G350-A2
Fig 1: Exploded View Of Transmission Case & Shift Components
GF0046439Courtesy of FORD MOTOR CO.
Item Part Number Description
1 7A508 Slave cylinder and release bearing
2 7500 Clutch housing
3 7K584 Slave cylinder line retainer
4 7050 Input shaft bearing retainer
5 7052 Input shaft seal
6 7W425 Shaft bearing
7 7005 Main case
8 7A443 Main case-to-clutch housing bolt
9 87675-S Drain and fill plugs
10 7K024 Reverse lever pivot bolt
11 15520 Reverse lamp switch
12 7K024 Shift lever reverse pin
13 7W425 Shaft bearing
14 7H103 Output Shaft Speed (OSS) sensor
15 7A039 Extension housing
16 7065 Extension housing bearing
17 7109 Extension housing bearing snap ring
18 7052 Output shaft seal
19 7K359 Transmission flange
20 7E397 Flange seal
21 7119 Thrust washer
22 7K440 Output flange nut
23 7A443 Gear shift cover bolt
24 7222 Gear shift cover
25 7240 Shift rail selector
26 7052 Selector rail seal
27 7N094 Selector finger
28 7F018 Gearshift offset lever
29 7234 Shifter detents
30 7127 Main shift rail bearings
31 7358 Main shift control shaft
32 87038-S91 Main shift rail seal
33 7222 Transmission case cover
34 7W425 Main shift control shaft bushings
35 7230 3rd/4th gear shift fork
36 7L082 Shift fork inserts
37 7N232 Gear shift plate
38 7302 Selector body
39 7K201 Gear selector interlock sleeve
40 7N232 Gear shift plate
41 7230 1st/2nd gear shift fork
42 7240 Reverse gear shift rail
43 7230 Reverse shift fork
44 7E485 Reverse shift fork spring
45 7K002 Reverse gearshift lever
46 7230 5th gear shift fork
47 7E397 Reverse gear overtravel stop
48 7141 Reverse idler gear and bushing
49 357479-S15 Pin
50 7140 Reverse idler gear shaft
    NOTE: Soak the blocking rings in transmission fluid for 10 minutes.
  1. Lubricate all components with transmission fluid during assembly.
  2. If removed, install new rail bearings into the transmission case.
  3. If removed, install new main shift rail bearings into the extension housing.
  4. Position the countershaft cluster gear in the case.
    5. Fig 2: Positioning Countershaft Cluster Gear In Case
    GF0015785Courtesy of FORD MOTOR CO.
    NOTE: Failure to correctly support the case during bearing installation will result in permanent distortion of the case.
  5. Using the Bearing Tube Remover/Installer and Torrington Bearing Installer and a press, install the rear countershaft bearing assembly.
    1. Position two 6.35 mm (0.25 in) pieces of bar stock between the countershaft and the case.
    2. Press the rear countershaft bearing assembly in the case.
    6. Fig 3: Installing Rear Countershaft Bearing Assembly
    GF0015786Courtesy of FORD MOTOR CO.
  6. Position the reverse idler gear and bushing in the case with the shift lever groove facing the rear of the case. Install the reverse idler gear shaft and the reverse gear overtravel stop.
    7. Fig 4: Positioning Reverse Idler Gear And Bushing In Case
    GF0015787Courtesy of FORD MOTOR CO.
  7. Install the rear countershaft bearing cup.
    8. Fig 5: Installing Rear Countershaft Bearing Cup
    GF0001076Courtesy of FORD MOTOR CO.
    NOTE: Do not install the shims at this time.
  8. Install the countershaft rear bearing retainer.
    • Tighten to 21 Nm (15 lb-ft).
    9. Fig 6: Installing Countershaft Rear Bearing Retainer
    GF0015788Courtesy of FORD MOTOR CO.
  9. Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, measure the countershaft cluster gear end play.
    • If the end play is not within specification, remove the countershaft rear bearing retainer and install the necessary thickness shim(s). Reinstall the countershaft rear bearing retainer and recheck the end play.
    • Bend the tabs of the countershaft rear bearing retainer over the bolts when the end play adjustment is complete.
    10. Fig 7: Bending Tabs Of Countershaft Rear Bearing Retainer Over Bolts When End Play Adjustment Is Complete
    GF0046440Courtesy of FORD MOTOR CO.
  10. Install a new roll pin.
    11. Fig 8: Removing/Installing Roll Pin Using A Suitable Punch
    GF0001046Courtesy of FORD MOTOR CO.
  11. Align the reverse gearshift lever, the reverse shift fork and the reverse positioning spring.
    12. Fig 9: Aligning Reverse Gearshift Lever
    GF0001078Courtesy of FORD MOTOR CO.
    NOTE: Observe the reverse positioning spring rotation. The spring must rotate counterclockwise into its installed position.
  12. Install the reverse shift fork.
    • Place the reverse idler gear and bushing into the NEUTRAL position. Align the reverse shift fork and the reverse idler gear and bushing. Push downward on the reverse shift fork until fully engaged into the reverse idler gear and bushing.
    13. Fig 10: Identifying Idler Gear And Bushing Into Neutral Position
    GF0015789Courtesy of FORD MOTOR CO.
  13. Install the output shaft assembly.
    14. Fig 11: Installing Output Shaft Assembly
    GF0015790Courtesy of FORD MOTOR CO.
  14. Apply pipe sealant to the shift lever reverse pin threads. Position the looped end of the reverse positioning spring around the shift lever reverse pin. Install the pin.
    15. Fig 12: Locating Shift Lever Reverse Pin
    GF0015791Courtesy of FORD MOTOR CO.
    NOTE: Coat the 15 bearings, the spacer, the thrust bearing and the thrust washer with grease.
  15. Install the roller bearings, the input shaft bearing spacer, the thrust bearing and the thrust washer.
    16. Fig 13: Identifying 4th Gear Synchronizer Ring, Thrust Washer, Thrust Bearing & Input Shaft Bearing Spacer
    GF0001041Courtesy of FORD MOTOR CO.
  16. Align the notches in the synchronizer blocking ring and the synchronizer hub inserts. Install the 4th gear synchronizer blocking ring.
    17. Fig 14: Locating 4th Gear Synchronizer Blocking Ring
    GF0015792Courtesy of FORD MOTOR CO.
    NOTE: Verify that the 4th speed synchronizer blocking ring is still in position.
  17. Align the flat on the 4th gear clutching teeth with the countershaft cluster gear, then install the input shaft.
    18. Fig 15: Locating Input Shaft
    GF0015793Courtesy of FORD MOTOR CO.
    NOTE: Do not install the end play shims at this time.
    NOTE: Do not apply sealant to the input shaft bearing retainer at this time.
  18. Install the bearing race in the bearing retainer.
    19. Fig 16: Locating Bearing Race In Bearing Retainer
    GF0015794Courtesy of FORD MOTOR CO.
  19. Install the input shaft bearing retainer with the notch facing upward.
    20. Fig 17: Locating Input Shaft Bearing Retainer With Notch Facing Upward
    GF0001079Courtesy of FORD MOTOR CO.
  20. Install the 4 input shaft bearing retainer bolts.
    • Tighten to 21 Nm (15 lb-ft).
    21. Fig 18: Locating Input Shaft Bearing Retainer Bolts
    GF0015795Courtesy of FORD MOTOR CO.
  21. Install 5th gear and the output shaft rear bearing cup.
    22. Fig 19: Locating 5th Gear & Output Shaft Rear Bearing Cup
    GF0001080Courtesy of FORD MOTOR CO.
  22. Install the reverse gear shift rail. Align the ball stud with the slot in the case and align the reverse gear shift rail with the reverse shift fork. Once the ball stud enters the case, rotate the reverse gear shift rail until the ball aligns with the reverse gearshift lever. Rotate the reverse gear shift rail counterclockwise until the ball stud fully engages the reverse gearshift lever.
    23. Fig 20: Installing reverse gear shift rail
    GF0001081Courtesy of FORD MOTOR CO.
  23. Install the 5th gear shifter fork, the synchronizer blocking ring, the synchronizer assembly and the 5th gear shifter fork pin as an assembly.
    24. Fig 21: Installing 5th Gear Shifter Fork, Synchronizer Blocking Ring, Synchronizer Assembly & 5th Gear Shifter Fork Pin
    GF0001082Courtesy of FORD MOTOR CO.
    NOTE: To prevent component damage when installing the extension housing, the alignment tab on the reverse brake ring must engage the alignment slot in the extension housing.
  24. Install the synchronizer blocking ring, the reverse brake ring, the thrust washer and a new 5th speed synchronizer retaining snap ring.
    25. Fig 22: Installing Synchronizer Blocking Ring, Reverse Brake Ring, Thrust Washer & 5th Speed Synchronizer Retaining Snap Ring
    GF0001083Courtesy of FORD MOTOR CO.
  25. Apply pipe sealant to the reversing lamp switch threads and install the switch.
    26. Fig 23: Locating Reversing Lamp Switch
    GF0015751Courtesy of FORD MOTOR CO.
  26. Install the reverse gearshift lever retaining clip.
    27. Fig 24: Locating Reverse Gearshift Lever Retaining Clip
    GF0001084Courtesy of FORD MOTOR CO.
    NOTE: Do not, under any circumstance, apply silicone sealant to the top of the transmission case. The sealant could fall into the transmission and affect transmission operation.
  27. Apply a 3.2 mm (1/8 in) bead of silicone rubber to the sealing surface on the case cover.
    28. NOTE: Verify that all of the synchronizers are in the NEUTRAL position and the gear shifter forks in the cover are in the NEUTRAL position.
  28. Position the case cover toward the filler plug side of the transmission and lower it until the gear shifter forks engage the synchronizers. Continue to lower the cover and move it into position to engage the reverse gearshift lever.
    29. Fig 25: Locating Case Cover And Bolts
    GF0015746Courtesy of FORD MOTOR CO.
  29. Install the 10 transmission case cover bolts.
    • Tighten to 12 Nm (106 lb-in).
  30. Install a new output shaft bearing and a new snap ring.
    31. Fig 26: Locating Output Shaft Bearing
    GF0015742Courtesy of FORD MOTOR CO.
  31. Using the Transmission Extension Housing Oil Seal Installer, install a new output shaft seal.
    32. Fig 27: Installing Output Shaft Seal
    GF0015796Courtesy of FORD MOTOR CO.
  32. Install the large output shaft spacer.
    33. Fig 28: Locating Large Output Shaft Spacer
    GF0015744Courtesy of FORD MOTOR CO.
  33. Install a new check ball.
    34. Fig 29: Locating Check Ball
    GF0001040Courtesy of FORD MOTOR CO.
  34. Install the small output shaft spacer.
    35. Fig 30: Locating Small Output Shaft Spacer
    GF0015743Courtesy of FORD MOTOR CO.
  35. Apply a 3.2 mm (1/8 in) bead of silicone rubber to the sealing surface on the extension housing.
    36. Fig 31: Locating Bead Of Silicone Rubber To Sealing Surface On Extension Housing
    GF0015797Courtesy of FORD MOTOR CO.
  36. Lubricate the detent plate. Position the gearshift offset lever in the extension housing.
    37. NOTE: To prevent component damage, the alignment tab on the reverse brake ring must align with the alignment slot in the extension housing.
    NOTE: Verify that the oil pick-up funnel engages the 5th gear synchronizer.
  37. Slide the gearshift offset lever onto the shift shaft and the position the extension housing into place.
    38. Fig 32: Locating Extension Housing And Gearshift Offset Lever
    GF0015798Courtesy of FORD MOTOR CO.
  38. Install the identification tag and the 8 extension housing bolts.
    • Tighten to 54 Nm (40 lb-ft).
    39. Fig 33: Locating Identification Tag & Extension Housing Bolts
    GF0001039Courtesy of FORD MOTOR CO.
  39. Install a new gearshift offset lever roll pin.
    40. Fig 34: Locating Gearshift Offset Lever Roll Pin
    GF0001038Courtesy of FORD MOTOR CO.
  40. Install the shift lever and the gearshift shaft.
    41. Fig 35: Locating Shift Lever & Gearshift Shaft
    GF0001037Courtesy of FORD MOTOR CO.
  41. Install the shift lever detents.
    • Tighten to 40 Nm (30 lb-ft).
    42. Fig 36: Locating Shift Detents
    GF0001035Courtesy of FORD MOTOR CO.
  42. Install a new gearshift lever roll pin.
    43. Fig 37: Installing New Gearshift Lever Roll Pin
    GF0001034Courtesy of FORD MOTOR CO.
  43. Using the Dial Indicator Gauge with Holding Fixture, measure the output shaft end play.
    1. Place the transmission in a vertical position.
    2. Install the Dial Indicator Gauge with Holding Fixture.
    3. Push upward on the input shaft and record the dial indicator reading.
    44. Fig 38: Measuring Output Shaft End Play
    GF0015799Courtesy of FORD MOTOR CO.
    NOTE: Although zero end play is the ideal, end play up to 0.230 mm (0.009 in) is an acceptable tolerance. Do not overload the bearings with a shim that is too thick as damage may occur.
    NOTE: Select a shim with a thickness equal to the dial indicator reading. This will provide zero end play. Install the thickest shim closest to the front bearing cup to provide support for the cup.
  44. Rotate the transmission to the horizontal position and remove the input shaft bearing retainer. Remove the bearing race and install the necessary shim(s).
    45. Fig 39: Locating Input Shaft Bearing Cup
    GF0015758Courtesy of FORD MOTOR CO.
  45. Apply a 3.2 mm (1/8 in) bead of silicone rubber to the sealing surface on the input shaft bearing retainer. Do not cover the notch in the input shaft bearing retainer with sealer.
  46. Install the input shaft bearing retainer and the 4 bolts.
    • Tighten to 21 Nm (15 lb-ft).
    47. Fig 40: Locating Input Shaft Bearing Retainer Bolts
    GF0015795Courtesy of FORD MOTOR CO.
  47. Apply a 3.2 mm (1/8 in) bead of silicone rubber to the sealing surface on the gearshift lever.
  48. Install the shift cover plate and the 4 shift cover plate bolts.
    • Tighten to 19 Nm (168 lb-in).
    49. Fig 41: Locating Shift Cover Plate Bolts
    GF0001033Courtesy of FORD MOTOR CO.
    NOTE: Apply thread sealant to the drain plug threads.
  49. Install the drain plug.
    • Tighten to 18 Nm (159 lb-in).
    50. Fig 42: Locating Drain Plug
    GF0015736Courtesy of FORD MOTOR CO.
  50. Install the Output Shaft Speed (OSS) sensor.
    • Tighten to 10 Nm (89 lb-in).
    51. Fig 43: Locating Output Shaft Speed Sensor
    GF0015740Courtesy of FORD MOTOR CO.
  51. Position the output flange onto the output shaft. Install the thrust washer and output flange nut. Tighten until the output flange is fully seated.
  52. Remove the output flange nut and thrust washer.
  53. Install a new flange seal. Carefully push it through until it is fully seated against the flange and output flange pocket.
  54. Install the thrust washer and output flange nut.
    • Tighten to 142 Nm (105 lb-ft).
  55. Install the clutch housing to the transmission.
    • Tighten to 31 Nm (23 lb-ft).
    56. Fig 44: Locating Clutch Housing Bolts
    GF0015800Courtesy of FORD MOTOR CO.
  56. Install a new clutch slave cylinder retaining clip.
  57. Install the clutch release slave cylinder.
    • Tighten to 9 Nm (80 lb-in).
    58. Fig 45: Locating Clutch Release Slave Cylinder
    GF0015738Courtesy of FORD MOTOR CO.
scientia non olet · About LEMON Manuals