LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2009 >> Flex Limited, FWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1490 (Manual Transmission - Tr6060) >> Assembly >> Transmission

Section 1490 (Manual Transmission - Tr6060): 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
GF0000024Courtesy of FORD MOTOR CO.
 Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent
GF0000940Courtesy of FORD MOTOR CO.
 Holding Fixture, Transmission 307-003 (T57L-500-B)
GF0001106Courtesy of FORD MOTOR CO.
 Adapter for 303-224 (Handle) 205-153 (T80T-4000-W)
GF0001055Courtesy of FORD MOTOR CO.
 Installer, Input Shaft Oil Seal 308-220 (T94P-7025-AH)
GF0000771Courtesy of FORD MOTOR CO.
 Gauge, Clutch Housing 308-021 (T75L-4201-A)
GF0001068Courtesy of FORD MOTOR CO.
 Remover/Installer, Bearing Tube 308-024 (T75L-7025-B)
GF0001104Courtesy of FORD MOTOR CO.
 Replacer/Adapter 308-239 (T96P-7025-A)
Material

Item Specification
MERCON® V Automatic Transmission Fluid
XT-5-QM (or XT-5-QMC) (US); CXT-5-LM12 (Canada)		 MERCON® V
Premium Long-Life Grease
XG-1-C or XG-1-K (US); CXG-1-C (Canada)		 ESA-M1C75-B
Silicone Gasket and Sealant
TA-30		 WSE-M4G323-A4
Threadlock and Sealer
TA-25		 WSK-M2G351-A5
Fig 1: Disassembled View Of Transmission Case & Shift Components
GF0046456Courtesy of FORD MOTOR CO.
Item Part Number Description
1 7W425 Shift rail bushing
2 7A082 Roll pin
3 7241 Reverse shift rail lever
4 7A082 Snap ring
5 7W425 Shift rail bushing
6 7241 5th/6th outer shift rail lever
7 7241 5th/6th outer shift lever pad
8 7241 5th/6th inner shift rail lever
9 7W425 Shift rail bushing
10 7L082 3rd/4th shift fork pad
11 7241 Washer
12 7230B 3rd/4th shift fork
13 7241 5th/6th shift rail
14 7A082 Roll pin
15 7L082 Reverse shift fork pad
16 7241 Shift rail collar
17 7230 Reverse shift fork
18 7241 Washer
19 7W425 Shift rail bushing
20 7L267 1st/2nd, 3rd/4th shift rail
21 7L082 5th shift fork pad
22 7230 5th shift fork
23 7A082 Roll pins
24 7814 Selector pin
25 7K201 Interlock plate
26 7L082 1st/2nd shift fork pad
27 7230 1st/2nd shift fork
28 - Shift gate
29 7A082 Roll pins
30 7C453 Shift cover assembly
31 - Shift cover bolt (4 required)
32 - Shift guide rail
33 - Shift guide plate bolt (2 required)
34 7F476 Shift guide plate
35 7A508 Clutch slave cylinder
36 6392 Clutch housing
37 7234 Shift detent plug
38 7234 Shift detent spring
39 7234 Shift detent
40 7127 Top shift rail bearing
41 7052 Input shaft seal
42 7005 Transmission main case
43 7A082 Snap ring
44 7025 Output shaft bearing cup
45 7A010 Case plug
46 7A443 Output shaft speed (OSS) sensor bolt
47 7H103 OSS sensor
48 7025 Output shaft bearing
49 7A082 Output shaft bearing snap ring
50 7052 Extension housing seal
51 7089 Output flange
52 7119 Thrust washer
53 7K440 Output flange nut
54 - Reverse lockout solenoid bolt
55 7374 Reverse lockout solenoid
56 7A039 Extension housing
57 7L027 Magnet
Fig 2: Disassembled View Of Transmission Gear Assemblies
GF0046457Courtesy of FORD MOTOR CO.
Item Part Number Description
1 7025 Input shaft bearing
2 7017 Input shaft
3 - Output shaft bearing race
4 7025 Output shaft front bearing
5 7A082 Snap ring
6 7124 3rd/4th synchronizer assembly
7 7107 3rd/4th synchronizer blocking ring assembly
8 7117 Spacer
9 7025 3rd gear needle bearing
10 7B340 3rd gear
11 7061 Output shaft
12 7025 2nd gear needle bearing
13 7102 2nd gear
14 7117 Spacer
15 7107 2nd gear synchronizer blocking ring assembly
16 7124 1st/2nd synchronizer assembly
17 7117 1st gear synchronizer blocking ring assembly
18 7050 Spacer
19 7025 1st gear needle bearing
20 7100 1st gear
21 7025 Output shaft rear bearing
22 7025 Output shaft bearing race
23 7L047 6th driven gear
24 7K316 5th driven gear
25 7A082 Thrust washer
26 7A082 Split washer
27 - Synchronizer cone (part of 7107)
28 7124 Reverse synchronizer assembly
29 7A082 Snap ring
30 7107 Reverse gear synchronizer blocking ring assembly
31 7C238 Reverse gear
32 7N168 Reverse gear needle bearing
33 7A385 Thrust washer
34 7A082 Snap ring
35 7A082 Spacer
36 7025 Rear output shaft bearing
37 7A082 Spacer
38 7A082 Snap ring
39 7E172 Check ball
40 7H150 Speedometer rotor
41 7A082 Snap ring
42 7L172 Shim
43 7025 Countershaft front bearing race
44 7025 Countershaft front bearing
45 7113 Countershaft
46 7025 Countershaft rear bearing
47 7025 Countershaft rear bearing race
48 7025 Thrust washer
49 7146 6th gear
50 7025 6th gear needle bearing
51 7107 Synchronizer blocking ring assembly
52 7124 5th/6th synchronizer assembly
53 7107 Synchronizer blocking ring assembly
54 7117 Spacer
55 7A082 Snap ring
56 7144 5th gear
57 7025 5th gear needle bearing
58 7025 Thrust washer
59 7A082 Snap ring
60 - Reverse driver gear
61 7A082 Snap ring
62 7C211 Reverse idler shroud bracket bolt
63 7723 Reverse idler shaft bracket
64 7141 Reverse idler gear
65 7025 Reverse idler gear needle bearing
66 7140 Reverse idler gear shaft
  1. Lubricate all components with transmission fluid during assembly.
  2. Attach the transmission clutch housing to the special tool.
    3. NOTE: If a new front input shaft bearing or front countershaft bearing was installed, install the new bearing cups.
  3. Install the input shaft bearing cup and the countershaft bearing cup. Do not install the shims at this time.
  4. Install the input shaft.
  5. Install the output shaft onto the input shaft.
  6. Install the countershaft.
    • Lift the output shaft upward, tilt the countershaft and install.
    7. Fig 3: Locating Countershaft
    GF0001218Courtesy of FORD MOTOR CO.
  7. Install the transmission case and tighten the bolts.
    • Tighten to 35 Nm (26 lb-ft).
    8. Fig 4: Locating Clutch Housing-To-Transmission Case Bolts
    GF0001157Courtesy of FORD MOTOR CO.
    NOTE: Rotate the input shaft/output shaft to seat the bearings.
  8. Using the special tools, measure the input shaft/output shaft end play by applying an upward load on the input shaft. Record the measurement.
    • Input/output shaft preload specification is 0.0127-0.0889 mm (0.0005-0.0035 in).
    9. Fig 5: Measuring Input Shaft/Output Shaft End Play By Applying An Upward Load On Input Shaft Using Special Tools
    GF0001219Courtesy of FORD MOTOR CO.
  9. Reposition the special tool on the countershaft.
    10. NOTE: Rotate the countershaft to seat the bearings.
  10. Using the special tools, measure the countershaft gear end play by pulling upward on the countershaft. Record the measurement.
    • Countershaft preload specification is 0.0127-0.0889 mm (0.0005-0.0035 in).
    11. Fig 6: Measuring Countershaft Gear End Play By Pulling Upward On Countershaft Using Special Tools
    GF0001220Courtesy of FORD MOTOR CO.
  11. Remove the transmission case.
  12. Remove the countershaft.
  13. Remove the output shaft.
  14. Remove the input shaft.
  15. Remove the input shaft bearing cup and the countershaft bearing cup.
  16. Using the recorded end play measurements, select and install the appropriate shims to achieve the correct end play. Install the front input shaft bearing cup and the front countershaft bearing cup.
    • Lubricate the bearing cups with petroleum jelly.
    17. Fig 7: Locating Input Shaft Bearing Cup
    GF0001164Courtesy of FORD MOTOR CO.
    Fig 8: Locating Countershaft Bearing Cup
    GF0001165Courtesy of FORD MOTOR CO.
  17. Using the special tools, install the new input shaft seal.
    18. Fig 9: Installing New Input Shaft Seal
    GF0001221Courtesy of FORD MOTOR CO.
  18. Install the input shaft and 4th gear synchronizer blocking ring.
    19. Fig 10: Installing Input Shaft & 4th Gear Synchronizer Blocking Ring
    GF0001222Courtesy of FORD MOTOR CO.
  19. Assemble the shift rail assembly to the output shaft, then install the output shaft and shift rail as an assembly.
    • Rotate the output shaft to engage the 4th gear synchronizer blocking ring with the synchronizer keys.
    20. Fig 11: Rotating Output Shaft To Engage 4th Gear Synchronizer Blocking Ring With Synchronizer Keys
    GF0001223Courtesy of FORD MOTOR CO.
  20. Lift up the output shaft, then install the countershaft.
    21. Fig 12: Locating Countershaft
    GF0001224Courtesy of FORD MOTOR CO.
  21. Install the 6th gear spacer and thrust washer.
    22. Fig 13: Locating 6th Gear Spacer & Thrust Washer
    GF0001160Courtesy of FORD MOTOR CO.
  22. Install the 5th/6th and reverse shift rail assembly and align the slots of the shift levers with the shift interlock plate.
    23. Fig 14: Locating 5th/6th & Reverse Shift Rail Assembly
    GF0001225Courtesy of FORD MOTOR CO.
  23. Clean the mating surfaces of the transmission main case and the transmission clutch housing. Apply a bead of silicone rubber to the sealing surface on the transmission clutch housing. Install the transmission main case and the front offset lever.
    • Make sure the transmission is in NEUTRAL to keep the 3rd/4th gear shift rail from engaging. Check for correct alignment of roller with top shift rail.
    • Tighten the bolts in a star pattern to 35 Nm (26 lb-ft).
    24. Fig 15: Making Sure Transmission Is In Neutral To Keep 3rd/4th Gear Shift Rail From Engaging
    GF0001226Courtesy of FORD MOTOR CO.
    Fig 16: Locating Clutch Housing-To-Transmission Case Bolts
    GF0001157Courtesy of FORD MOTOR CO.
  24. Apply threadlock and sealer to the threads of the shift lever guide bolts, then install the bolts.
    • Tighten to 22 Nm (16 lb-ft).
    • Pull up on the 5th/6th shift rail to align the slot of the interlock plate with the guide bolt hole.
    25. Fig 17: Locating Shift Lever Guide Bolts
    GF0001158Courtesy of FORD MOTOR CO.
  25. Install a new front offset lever roll pin.
    • Install the pin until it is flush with the lever.
  26. Apply threadlock and sealer to the threads of the shift detent, then install the shift detent assembly.
    • Tighten to 40 Nm (30 lb-ft).
    27. Fig 18: Locating New Front Offset Lever Roll Pin
    GF0001227Courtesy of FORD MOTOR CO.
  27. Install the 5th/6th gear needle bearing.
  28. Install 5th/6th gear, then install the 5th/6th gear synchronizer double cone and blocking ring as an assembly.
    • Before installing the blocking ring, index-mark the blocking ring to the synchronizer hub.
    29. Fig 19: Locating 5th/6th Gear Synchronizer Intermediate Cone, Outer Cone & Blocking Ring
    GF0001155Courtesy of FORD MOTOR CO.
  29. Install the 5th/6th gear shift fork and the 5th/6th gear synchronizer as an assembly.
    • The synchronizer hub has a tight fit on the shaft, and may need to be installed separately.
    • Make sure the synchronizer hub is correctly aligned with the blocking ring.
  30. Install the new 5th/6th shift fork snap ring.
    31. Fig 20: Locating 5th/6th Gear Shift Fork & 5th/6th Gear Synchronizer
    GF0001146Courtesy of FORD MOTOR CO.
  31. Install the snap ring on the countershaft.
    32. Fig 21: Locating Snap Ring On Countershaft
    GF0001152Courtesy of FORD MOTOR CO.
  32. Install the 5th/6th gear synchronizer double cone and blocking ring as an assembly.
    33. Fig 22: Locating 5th/6th Gear Synchronizer Intermediate Cone, Outer Cone & Blocking Ring
    GF0001151Courtesy of FORD MOTOR CO.
  33. Install the spacer and the 5th drive gear needle bearing.
    34. Fig 23: Locating 5th/6th Drive Gear Needle Bearing & Spacer
    GF0001150Courtesy of FORD MOTOR CO.
  34. Install the following components:
    • The 5th drive gear.
    • The 5th drive gear thrust washer.
    • A new 5th drive gear snap ring.
  35. Using a suitable driver, install the reverse drive gear.
  36. Install a new reverse drive gear snap ring.
    37. Fig 24: Locating Reverse Drive Gear Snap Ring
    GF0001147Courtesy of FORD MOTOR CO.
  37. Using the special tool, press the 5th driven gear.
    • Align the splines of the 5th driven gear with the drive gear on the countershaft extension.
  38. Install the split ring and retainer.
    39. Fig 25: Pressing 5th Driven Gear Using Special Tool
    GF0001228Courtesy of FORD MOTOR CO.
  39. Install the reverse shift fork, the reverse synchronizer and the strut retainer as an assembly.
    • The synchronizer hub has a tight fit on the shaft and may need to be installed separately.
    40. Fig 26: Locating Reverse Shift Fork, Reverse Synchronizer & Strut Retainer
    GF0001142Courtesy of FORD MOTOR CO.
  40. Install the reverse shift fork snap ring.
    41. Fig 27: Locating Reverse Shift Fork Snap Ring
    GF0001141Courtesy of FORD MOTOR CO.
  41. Install a new reverse gear synchronizer snap ring.
  42. Install the reverse gear synchronizer blocking rings.
    43. Fig 28: Locating Reverse Gear Synchronizer Blocking Rings
    GF0001139Courtesy of FORD MOTOR CO.
  43. Install the reverse gear needle bearing.
    44. Fig 29: Locating Reverse Gear Needle Bearing
    GF0001138Courtesy of FORD MOTOR CO.
  44. Install reverse gear.
    45. Fig 30: Locating Reverse Gear
    GF0001229Courtesy of FORD MOTOR CO.
  45. Install the reverse gear thrust washer.
    46. Fig 31: Locating Reverse Gear Thrust Washer
    GF0001230Courtesy of FORD MOTOR CO.
  46. Install a new reverse gear snap ring.
    47. Fig 32: Locating New Reverse Gear Snap Ring
    GF0001231Courtesy of FORD MOTOR CO.
  47. Install the lower spacer, the rear output shaft roller bearing and the upper spacer.
    48. Fig 33: Locating Lower Spacer, Rear Output Shaft Roller Bearing & Upper Spacer
    GF0001232Courtesy of FORD MOTOR CO.
  48. Install the rear output shaft roller bearing snap ring.
    49. Fig 34: Locating Rear Output Shaft Roller Bearing Snap Ring
    GF0001233Courtesy of FORD MOTOR CO.
  49. Position the check ball on the shaft. Install the output shaft speed (OSS) sensor tone wheel. Install a new OSS sensor tone wheel retaining ring.
  50. Install the reverse shift rail, then install a new reverse shift rail roll pin.
    • Install the pin until it is flush with the lever.
  51. Install the bearing spacer and the race.
    52. Fig 35: Installing Bearing Spacer & Race
    GF0001234Courtesy of FORD MOTOR CO.
  52. Clean the mating surfaces of the transmission main case and the extension housing. Apply a bead of silicone rubber to the sealing surface on the transmission case. Install the extension housing and tighten the bolts.
    • Tighten to 48 Nm (25 lb-ft).
  53. Install the vent hose.
  54. Install the shift detent cover and the 4 shift detent cover bolts.
    • Tighten to 20 Nm (15 lb-ft).
    55. Fig 36: Locating Shift Detent Cover & Shift Detent Cover Bolts
    GF0001131Courtesy of FORD MOTOR CO.
  55. Install the output shaft flange.
  56. Install the output shaft flange nut as follows:
    • Using the old flange nut, tighten to 135 Nm (100 lb-ft).
    • Remove the nut and discard.
    • Install a new flange nut and tighten to 142 Nm (105 lb-ft).
    57. Fig 37: Identifying Output Shaft Flange & Nuts
    GF0001129Courtesy of FORD MOTOR CO.
  57. Apply thread sealer to the plug threads. Install the drain plug.
    • Tighten to 27 Nm (20 lb-ft).
    58. Fig 38: Locating Drain Plug
    GF0001128Courtesy of FORD MOTOR CO.
  58. Install the clutch slave cylinder and the 2 clutch slave cylinder bolts.
    • Tighten to 12 Nm (9 lb-ft).
    59. Fig 39: Locating Clutch Slave Cylinder & Clutch Slave Cylinder Bolts
    GF0001126Courtesy of FORD MOTOR CO.
  59. Install the clip and the line connector.
scientia non olet · About LEMON Manuals