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Section 901 (Manual Transmission): Assembly: Transmission: Assembly

WARNING: This page is about a different car, the 2007 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the countershaft cluster gear.
    Fig 1: Locating Countershaft Cluster Gear
    GF0010566Courtesy of FORD MOTOR CO.
  2. Position the input shaft.
    Fig 2: Locating Input Shaft & Bearing
    GF0003969Courtesy of FORD MOTOR CO.
    3. NOTE: Make sure the 4th gear synchronizer blocking ring is in place.
    Fig 3: Locating Output Shaft
    GF0010513Courtesy of FORD MOTOR CO.
  3. Install the output shaft.
  4. Mate the input shaft and output shaft together.
  5. Install the countershaft pilot bearings on both ends.
    Fig 4: Locating Countershaft Pilot Bearings
    GF0010567Courtesy of FORD MOTOR CO.
  6. Install the output shaft rear bearing and input shaft bearing.
    Fig 5: Locating Output Shaft Rear Bearing
    GF0010568Courtesy of FORD MOTOR CO.
    7. NOTE: Install the rear bearing retainer with the arrow pointing to the top of the case.
    Fig 6: Identifying Rear Bearing Retainer
    GF0010504Courtesy of FORD MOTOR CO.
  7. Install the rear bearing retainer.
    • Position the rear bearing retainer.
    • Install the bolts.
      • Tighten to 22 Nm (16 lb-ft).
    8. NOTE: If any related parts (such as the output shaft and bearings) have been installed new, carry out the shim thickness selective procedure.
    Fig 7: Identifying Special Seal Installation Tool
    GF0010569Courtesy of FORD MOTOR CO.
  8. Using the special tool, install the front cover oil seal.
  9. Position the transmission with the bell housing facing up.
  10. Using the special tool, measure the input shaft bearing race depth.
    Fig 8: Measuring Input Shaft Bearing Race Depth
    GF0010570Courtesy of FORD MOTOR CO.
    • Record the reading on Line 2 of the selective shim equation chart.
  11. Using the special tool, measure the front bearing retainer depth.
    Fig 9: Measuring Front Bearing Retainer Depth
    GF0010571Courtesy of FORD MOTOR CO.
    • Record the reading on Line 1 of the selective shim equation chart.
  12. Calculate and select the correct output shaft shim. Refer to the Output Shaft Shim Selective Chart.
    SELECTIVE SHIM EQUATION CHART

    Step Measurement mm (in)
    Line 1 (Dimension B)  
    Line 2 (Dimension A)  
    Line 3 (Subtract line 2 from line 1)  
    OUTPUT SHAFT SHIM SELECTIVE CHART

    Total From Line 3 Part Number Thickness
    2.75-2.85 mm (0.108-0.112 in) E8TZ-7029-C 2.7 mm
    (0.106 in)
    2.85-2.95 mm (0.112-0.116 in) E8TZ-7029-D 2.8 mm
    (0.110 in)
    2.95-3.05 mm (0.116-0.120 in) E8TZ-7029-E 2.9 mm
    (0.114 in)
    3.05-3.15 mm (0.120-0.124 in) E8TZ-7029-F 3.0 mm
    (0.118 in)
    3.15-3.25 mm (0.124-0.127 in) E8TZ-7029-G 3.1 mm
    (0.122 in)
    3.25-3.35 mm (0.127-0.131 in) E8TZ-7029-H 3.2 mm
    (0.125 in)
    3.35-3.45 mm (0.131-0.135 in) E8TZ-7029-J 3.3 mm
    (0.129 in)
    3.45-3.55 mm (0.135-0.139 in) E8TZ-7029-K 3.4 mm
    (0.133 in)
    3.55-3.65 mm (0.139-0.143 in) E8TZ-7029-L 3.5 mm
    (0.137 in)
    3.65-3.75 mm (0.143-0.147 in) E8TZ-7029-M 3.6 mm
    (0.141 in)
    3.75-3.85 mm (0.147-0.151 in) E8TZ-7029-N 3.7 mm
    (0.145 in)
    3.85-3.95 mm (0.151-0.155 in) E8TZ-7029-P 3.8 mm
    (0.149 in)
    3.95-4.05 mm (0.155-0.159 in) E8TZ-7029-R 3.9 mm
    (0.153 in)
    4.05-4.15 mm (0.159-0.163 in) E8TZ-7029-A 4.0 mm
    (0.157 in)
    4.15-4.25 mm (0.163-0.167 in) E8TZ-7029-B 4.1 mm
    (0.161 in)
  13. Using the special tool, measure the countershaft bearing depth.
    Fig 10: Measuring Countershaft Bearing Depth
    GF0010572Courtesy of FORD MOTOR CO.
    • Record the reading on Line 1 of the countershaft spacer equation chart.
  14. Using the special tool, measure the countershaft bearing retainer depth.
    Fig 11: Measuring Countershaft Bearing Retainer Depth
    GF0010573Courtesy of FORD MOTOR CO.
    • Record the reading on Line 2 of the countershaft spacer equation chart.
  15. Calculate and select the correct countershaft spacer. Refer to the Countershaft Spacer Selective Chart.
    COUNTERSHAFT SPACER EQUATION CHART

    Step Measurement mm (in)
    Line 1 (Dimension C)  
    Line 2 (Dimension D)  
    Line 3 (add line 1 and line 2)  
    COUNTERSHAFT SPACER SELECTIVE CHART

    Total From Line 3 Part Number Thickness
    2.45-2.55 mm (0.096-0.100 in) E8TZ-7C434-A 2.3 mm
    (0.090 in)
    2.55-2.65 mm (0.100-0.104 in) E8TZ-7C434-B 2.4 mm
    (0.094 in)
    2.65-2.75 mm (0.104-0.108 in) E8TZ-7C434-C 2.5 mm
    (0.098 in)
    2.75-2.85 mm (0.108-0.112 in) E8TZ-7C434-D 2.6 mm
    (0.102 in)
    2.85-2.95 mm (0.112-0.116 in) E8TZ-7C434-E 2.7 mm
    (0.106 in)
    2.95-3.05 mm (0.116-0.120 in) E8TZ-7C434-F 2.8 mm
    (0.110 in)
    3.05-3.15 mm (0.120-0.124 in) E8TZ-7C434-G 2.9 mm
    (0.114 in)
    3.15-3.25 mm (0.124-0.127 in) E8TZ-7C434-H 3.0 mm
    (0.118 in)
    3.25-3.35 mm (0.127-0.132 in) E8TZ-7C434-J 3.1 mm
    (0.122 in)
    16. NOTE: If necessary, apply a light coat of grease to the countershaft spacer, shim and fluid baffle.
    Fig 12: Locating Fluid Baffle, Input Bearing Shim & Countershaft Bearing Shim
    GF0010507Courtesy of FORD MOTOR CO.
  16. Position the bearing shim, the fluid baffle, and the countershaft spacer onto the front bearing retainer.
    • Using gasket maker, apply a thin coat to the sealing surface of the case and the front bearing retainer.
    17. NOTE: To prevent damage to the fluid seal lip during assembly, tape the input shaft splines.
    NOTE: Apply silicone sealant to the bolt threads.
    Fig 13: Locating Front Bearing Retainer Bolts
    GF0010574Courtesy of FORD MOTOR CO.
  17. Install the front bearing retainer.
    • Tighten to 19 Nm (14 lb-ft).
  18. Position the oil passage.
    Fig 14: Positioning Oil Passage
    GF0010575Courtesy of FORD MOTOR CO.
    19. NOTE: Apply silicone sealant to the bolt threads.
    Fig 15: Locating Front Oil Cooler Tube Bolt
    GF0010576Courtesy of FORD MOTOR CO.
  19. Install the front oil cooler tube bolt.
    • Tighten to 9 Nm (80 lb-in).
  20. Install the output shaft 5th gear.
    Fig 16: Locating Output Shaft 5th Gear
    GF0010577Courtesy of FORD MOTOR CO.
  21. Install the locking ball.
  22. Install the race and the 5th gear split needle bearing on the countershaft.
    Fig 17: Locating Countershaft Fifth Gear Split Bearing & Race
    GF0010502Courtesy of FORD MOTOR CO.
  23. Install the countershaft 5th gear.
    Fig 18: Locating Countershaft 5th Gear
    GF0010578Courtesy of FORD MOTOR CO.
  24. Install the 5th/reverse shift lever through the case.
    Fig 19: Locating Fifth/Reverse Shift Lever Through Case
    GF0010579Courtesy of FORD MOTOR CO.
  25. Install the counter lever shaft assembly.
    Fig 20: Locating Counter Lever Shaft Plate
    GF0010580Courtesy of FORD MOTOR CO.
    • Tighten to 45 Nm (33 lb-ft).
    • Install the plate with the arrow pointing downward. The chamfer points upward on the shaft assembly.
  26. Install the countershaft 5th gear synchronizer blocking ring.
    Fig 21: Locating Countershaft 5th Gear Synchronizer Blocking Ring
    GF0010581Courtesy of FORD MOTOR CO.
    27. NOTE: The reference mark on the synchronizer sleeve must face toward the reverse gear.
    Fig 22: Installing Fifth/Reverse Shift Rail, Shift Fork & Synchronizer
    GF0010582Courtesy of FORD MOTOR CO.
  27. Install the 5th/reverse shift rail, the shift fork, and the synchronizer as an assembly.
  28. Install the 5th/reverse gear shift rail bolt.
    Fig 23: Locating 5th/Reverse Gear Shift Rail Bolt
    GF0010583Courtesy of FORD MOTOR CO.
    • Tighten to 25 Nm (18 lb-ft).
  29. Install the synchronizer split washer.
    Fig 24: Locating Synchronizer Split Washer
    GF0010584Courtesy of FORD MOTOR CO.
  30. Using a feeler gauge, check the clutch hub end play.
    Fig 25: Checking Clutch Hub End Play Using A Feeler Gauge
    GF0010585Courtesy of FORD MOTOR CO.
    • If the clutch hub end play is not within specification, select and install the correct split washer.
      SPLIT WASHER SELECT CHART

      Part Number Thickness
      E8TZ-7R482-A 3.0 mm (0.118 in)
      E8TZ-7R482-B 3.1 mm (0.122 in)
      E8TZ-7R482-C 3.2 mm (0.125 in)
      E8TZ-7R482-D 3.3 mm (0.129 in)
      E8TZ-7R482-E 3.4 mm (0.133 in)
      E8TZ-7R482-F 3.05 mm (0.120 in)
      E8TZ-7R482-G 3.15 mm (0.124 in)
      E8TZ-7R482-H 3.25 mm (0.127 in)
      E8TZ-7R482-J 3.35 mm (0.131 in)
      E8TZ-7R482-K 3.45 mm (0.135 in)
      E8TZ-7R482-L 3.50 mm (0.137 in)
  31. Install the thrust washer.
    Fig 26: Locating Thrust Washer
    GF0010494Courtesy of FORD MOTOR CO.
  32. Install the countershaft reverse gear.
    • Install the reverse synchronizer blocking ring.
    • Install the 2 countershaft reverse gear needle bearings.
      Fig 27: Installing Countershaft Reverse Gear Needle Bearings
      GF0010586Courtesy of FORD MOTOR CO.
    • Install the countershaft reverse gear.
  33. Measure the countershaft reverse gear end play.
    Fig 28: Measuring Countershaft Reverse Gear End Play
    GF0010587Courtesy of FORD MOTOR CO.
    • Install the thrust washer and hold it against the shoulder on the countershaft while checking the end play.
    • Determine the correct thrust washer to obtain the correct end play. Remove the reverse gear and install the appropriate thrust washer. Reinstall the reverse gear.
      THRUST WASHER SELECT CHART

      Part Number Thickness
      E8TZ-7C340-A 7.45 mm (0.293 in)
      E8TZ-7C340-B 7.65 mm (0.301 in)
      E8TZ-7C340-C 7.85 mm (0.309 in)
      E8TZ-7C340-D 7.35 mm (0.289 in)
      E8TZ-7C340-E 7.55 mm (0.297 in)
      E8TZ-7C340-F 7.75 mm (0.305 in)
  34. Install the output shaft spacer.
    Fig 29: Locating Output Shaft Spacer
    GF0010588Courtesy of FORD MOTOR CO.
  35. Install the output shaft reverse gear.
    Fig 30: Locating Output Shaft Reverse Gear
    GF0010589Courtesy of FORD MOTOR CO.
  36. Install the reverse idler gear.
    Fig 31: Locating Reverse Idler Gear
    GF0010590Courtesy of FORD MOTOR CO.
    37. NOTE: Reverse idler shaft bolt must be installed within 4 minutes after applying the thread sealant with PTFE.
    Fig 32: Locating Reverse Idler Shaft Bolt
    GF0010591Courtesy of FORD MOTOR CO.
  37. Install the reverse idler shaft bolt.
    • Tighten to 98 Nm (72 lb-ft).
    • Apply thread sealant to the reverse idler shaft bolt threads.
  38. Using the special tools, install the output shaft rear bearing.
    Fig 33: Identifying Special Tool For Output Shaft Rear Bearing
    GF0010592Courtesy of FORD MOTOR CO.
  39. Install the thrust washer and the countershaft rear bearing.
    Fig 34: Installing Thrust Washer & Countershaft Rear Bearing
    GF0010593Courtesy of FORD MOTOR CO.
  40. Lock the transmission into 1st and 3rd gear.
    Fig 35: Locking Transmission Onto First & Third Gear
    GF0010594Courtesy of FORD MOTOR CO.
  41. Using the Transmission Shaft Locknut Socket, install a new output shaft rear bearing lock nut.
    Fig 36: Locating Output Shaft Rear Bearing Lock Nut
    GF0010595Courtesy of FORD MOTOR CO.
    • Tighten to 216 Nm (159 lb-ft).
  42. Install a new countershaft lock nut.
    Fig 37: Locating Countershaft Lock Nut
    GF0010596Courtesy of FORD MOTOR CO.
    • Tighten to 162 Nm (119 lb-ft).
  43. Using the special tool, stake the output shaft rear bearing lock nut and the countershaft lock nut.
    Fig 38: Locating Output Shaft Rear Bearing Lock Nut & Countershaft Lock Nut
    GF0010597Courtesy of FORD MOTOR CO.
  44. Install the locating ball, the tone wheel and the tone wheel snap ring.
  45. Install the extension housing.
    Fig 39: Locating Extension Housing Bolt
    GF0010598Courtesy of FORD MOTOR CO.
    • Apply gasket maker to the mating surfaces before installing.
    • Tighten to 39 Nm (29 lb-ft).
  46. Using the special tool, install the extension housing seal.
    Fig 40: Identifying Special Tool On Extension Housing Seal
    GF0010599Courtesy of FORD MOTOR CO.
  47. Place the synchronizer sleeves in NEUTRAL.
    Fig 41: Locating Synchronizer Sleeves In Neutral
    GF0010600Courtesy of FORD MOTOR CO.
  48. Install the case cover with a new gasket.
    Fig 42: Locating Case Cover Bolt
    GF0010601Courtesy of FORD MOTOR CO.
    • Tighten to 19 Nm (14 lb-ft).
  49. If equipped, install the damper.
    Fig 43: Locating Damper Bolts
    GF0010602Courtesy of FORD MOTOR CO.
    • Tighten to 22 Nm (16 lb-ft).
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