Section 1488 (Manual Transmission - T5OD): Disassembly: 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
Courtesy of FORD MOTOR CO.	Holding Fixture, Transmission	307-003 (T57L-500-B)
Courtesy of FORD MOTOR CO.	Puller, Bearing	205-D064 (D84L-1123-A) or equivalent
Courtesy of FORD MOTOR CO.	Remover, Front Wheel Hub	205-D070 (D93P-1175-B) or equivalent
Courtesy of FORD MOTOR CO.	Remover/Installer, Front Wheel Hub	204-069 (T81P-1104-C)
Courtesy of FORD MOTOR CO.	Staking Tool, Lock nut	308-056 (T77J-7025-F)

Remove the clutch slave cylinder and the retaining clip. Discard the retaining clip.

Fig 1: Locating Clutch Release Slave Cylinder

Courtesy of FORD MOTOR CO.

Remove the 4 clutch housing bolts.
- Separate the clutch housing from the transmission.

Fig 2: Locating Clutch Housing Bolts

Courtesy of FORD MOTOR CO.

Fig 3: Locating Clutch Housing Bolts

Courtesy of FORD MOTOR CO.

Clean the transmission exterior with solvent and dry with compressed air. During disassembly, clean all components with solvent and dry with compressed air.

NOTE: Position the gearshift lever in NEUTRAL.

Attach the transmission to the Transmission Holding Fixture.

Fig 4: Identifying Special Tool 307-003

Courtesy of FORD MOTOR CO.

Remove the drain plug and drain the transmission fluid.

Fig 5: Locating Drain Plug

Courtesy of FORD MOTOR CO.

Remove the output shaft flange nut. Using the Front Wheel Hub Remover, remove the output shaft flange, the washer and the seal. Discard the seal.

Fig 6: Locating Output Shaft Flange

Courtesy of FORD MOTOR CO.

Remove the Output Shaft Speed (OSS) sensor.

Fig 7: Locating Output Shaft Speed Sensor

Courtesy of FORD MOTOR CO.

Remove the 4 bolts and pry the shift cover plate off.

Fig 8: Locating Shift Cover Plate Bolts

Courtesy of FORD MOTOR CO.

NOTE: Do not attempt to remove the gearshift offset lever with the extension housing bolted in place. A lug, located on the bottom of the gearshift offset lever, meshes with the detent plate preventing enough rearward movement of the gearshift offset lever to allow removal.

Using a suitable punch, remove the roll pin and discard.

Fig 9: Installing New Gearshift Lever Roll Pin

Courtesy of FORD MOTOR CO.

Remove the 2 shift detents.

Fig 10: Locating Shift Detents

Courtesy of FORD MOTOR CO.

Move the gearshift shaft rearward, then remove the shift lever. Remove the gearshift shaft.

Fig 11: Moving Gearshift Shaft Rearward, Then Removing Shift Lever

Courtesy of FORD MOTOR CO.

Fig 12: Locating Shift Lever & Gearshift Shaft

Courtesy of FORD MOTOR CO.

Using a suitable punch, remove the gearshift offset lever roll pin and discard.

Fig 13: Locating Gearshift Offset Lever Roll Pin

Courtesy of FORD MOTOR CO.

Remove the 7 extension housing bolts and the identification tag.
- Carefully pry the extension housing to break the gasket seal.

Fig 14: Locating Identification Tag & Extension Housing Bolts

Courtesy of FORD MOTOR CO.

Remove the extension housing and the gearshift offset lever as an assembly.
Remove the gearshift offset lever and the split pin.
Using a hammer and a drift, remove the output shaft seal from the inside. Discard the seal.

Fig 15: Locating Output Shaft Seal

Courtesy of FORD MOTOR CO.

Remove and discard the snap ring, then using a hammer and a drift, remove the output shaft bearing.

Fig 16: Locating Output Shaft Bearing

Courtesy of FORD MOTOR CO.

Remove the small output shaft spacer.

Fig 17: Locating Small Output Shaft Spacer

Courtesy of FORD MOTOR CO.

Remove the check ball.

Fig 18: Locating Check Ball

Courtesy of FORD MOTOR CO.

Remove the large output shaft spacer.

Fig 19: Locating Large Output Shaft Spacer

Courtesy of FORD MOTOR CO.

NOTE: Support the reverse gear shift rail with a block of wood to prevent damaging the shift rail.

Remove the roll pin and discard.

Fig 20: Locating Roll Pin

Courtesy of FORD MOTOR CO.

Remove the 10 case cover bolts. Carefully pry the case cover to break the gasket seal. Lift the case cover and slide it toward the filler plug side of the case to clear the reverse gearshift lever.

Fig 21: Locating Case Cover And Bolts

Courtesy of FORD MOTOR CO.

Rotate the transmission with the output shaft facing upward.
Remove the 5th speed synchronizer snap ring, the thrust washer, the reverse brake ring and the synchronizer blocking ring.
Remove the 5th speed cluster gear, the synchronizer blocking ring, the synchronizer assembly and the 5th gear shifter fork as an assembly.

Fig 22: Removing 5th Speed Cluster Gear, Synchronizer Blocking Ring, Synchronizer Assembly And 5th Gear Shifter Fork

Courtesy of FORD MOTOR CO.

Rotate the reverse gear shift rail clockwise to disengage the ball stud from the reverse gearshift lever. Pull the reverse gear shift rail rearward slightly. Rotate the reverse gear shift rail counterclockwise to align the ball stud with the slot in the case and remove the reverse gear shift rail.
Loosen the rear bearing cup in the case. Pull upward on the mainshaft and remove the 5th gear.
Rotate the transmission with the input shaft facing upward.

NOTE: The input shaft bearing retainer is notched. Carefully pry the retainer to break the gasket seal.

Remove the 4 input shaft bearing retainer bolts and the input shaft bearing retainer.

NOTE: Make sure not to drop the 15 roller bearings, the input shaft bearing spacer, the thrust bearing or thrust washer from the rear of the input shaft when removing.

NOTE: Rotate the input shaft until the flat on the 4th gear clutching teeth align with the countershaft cluster gear.

Remove the input shaft.
Remove the 4th gear synchronizer ring, the thrust washer, the thrust bearing, the input shaft bearing spacer and the 15 roller bearings.

Fig 23: Identifying 4th Gear Synchronizer Ring, Thrust Washer, Thrust Bearing & Input Shaft Bearing Spacer

Courtesy of FORD MOTOR CO.

NOTE: If the output shaft rear bearing cup sticks, it is misaligned in the case bore. To free the output shaft rear bearing cup, work the output shaft assembly back and forth in the case.

Remove the output shaft rear bearing cup.

Fig 24: Removing Output Shaft Rear Bearing Cup

Courtesy of FORD MOTOR CO.

Remove the output shaft assembly.
Using the Lock nut Staking Tool, flatten the tabs on the countershaft rear bearing retainer.

Fig 25: Locating Tabs On Countershaft Rear Bearing Retainer

Courtesy of FORD MOTOR CO.

Remove the 4 bolts, the countershaft rear bearing retainer and the shim.

Fig 26: Locating Countershaft Rear Bearing Retainer And Shim

Courtesy of FORD MOTOR CO.

NOTE: If the bearing race sticks in the case, it is misaligned in the case bore. To free the race, work the countershaft cluster gear back and forth.

Remove the bearing race.

Fig 27: Locating Bearing Race

Courtesy of FORD MOTOR CO.

Using the Front Wheel Hub Remover/Installer and Bearing Puller, remove the rear countershaft bearing assembly.

Fig 28: Identifying Special Tool 204-069 And 205-D064

Courtesy of FORD MOTOR CO.

Remove the reverse gearshift lever retaining clip.

Fig 29: Locating Reverse Gearshift Lever Retaining Clip

Courtesy of FORD MOTOR CO.

Using a Torx bit driver, remove the shift lever reverse pin.
Remove the reversing lamp switch.

Fig 30: Locating Reversing Lamp Switch

Courtesy of FORD MOTOR CO.

NOTE: Observe the location of the reverse gearshift lever, the reverse shift fork and the reverse positioning spring.

NOTE: Observe the rotation action of the reverse positioning spring.

NOTE: Hold the reverse gearshift lever and lift it upward as straight up as possible to remove the assembly.

Remove the reverse gearshift lever, the reverse shift fork and the reverse positioning spring as an assembly.

Fig 31: Locating Reverse Gearshift Lever & Reverse Shift Fork

Courtesy of FORD MOTOR CO.

Using a suitable punch, remove the roll pin and discard.

Fig 32: Removing/Installing Roll Pin Using A Suitable Punch

Courtesy of FORD MOTOR CO.

Remove the reverse idler gear shaft, the reverse idler gear and bushing and the reverse gear overtravel stop.

Fig 33: Removing Reverse Idler Gear Shaft

Courtesy of FORD MOTOR CO.

Move the countershaft cluster gear rearward through the bearing bore. Tilt the assembly upward and remove it from the case.

Fig 34: Removing Countershaft Cluster Gear

Courtesy of FORD MOTOR CO.

Inspect the rail bearing for wear or damage. Remove the bearing as necessary. Using a suitable puller, remove the rail bearing from the transmission. Discard the rail bearing.
Inspect the main shift rail bearings for wear or damage. Remove the bearings as necessary. Using a suitable puller, remove the main shift rail bearings from the extension housing. Discard the bearings.