Section 901 (Manual Transmission): Disassembly: Transmission

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.

Special Tools

Illustration	Tool Name	Tool Number
	Remover, Mainshaft Bearing	308-058 (T77J-7025-H)
	Remover, Front Cover	308-171 (T88T-7025-D)
	Socket, Transmission Shaft Locknut	308-168 (T88T-7025-AR)
	Remover/Installer, Bearing Tube	308-024 (T75L-7025-B)
	Remover, Transmission Fluid Seal	307-048 (T74P-77248-A)
	Screw, Bearing Removal Tube	308-092 (T84T-7025-B)

WARNING: Wear protective eyewear whenever using compressed air.

Clean the transmission exterior with solvent and dry with compressed air.

WARNING: Wear protective eyewear whenever using compressed air.

Clean all parts removed with solvent and dry with compressed air.
Set the transmission on a work bench.
Remove the shift control housing.

Fig 1: Identifying Shift Control Housing
Courtesy of FORD MOTOR CO.
- Remove the bolts.
- Remove the housing.
Using the special tool, remove the extension housing seal.

Fig 2: Identifying Special Seal Removal Tool
Courtesy of FORD MOTOR CO.
If equipped, remove the damper.

Fig 3: Locating Damper Bolt
Courtesy of FORD MOTOR CO.
Remove the 8 bolts and the extension housing.

Fig 4: Locating Extension Housing Bolts
Courtesy of FORD MOTOR CO.
Slide the 1st/2nd and 3rd/4th synchronizer sleeves forward to lock the transmission into 1st and 3rd gears.
Remove the tone wheel snap ring, the tone ring and the locating ball.

Fig 5: Locating Tone Wheel Snap Ring
Courtesy of FORD MOTOR CO.
Using the Transmission Shaft Locknut Socket, remove and discard the output shaft rear bearing lock nut.

Fig 6: Locating Output Shaft Rear Bearing Lock Nut
Courtesy of FORD MOTOR CO.
Remove and discard the countershaft lock nut.

Fig 7: Locating Countershaft Lock Nut
Courtesy of FORD MOTOR CO.
Remove the countershaft rear bearing and the countershaft rear bearing thrust washer.

Fig 8: Removing Countershaft Rear Bearing & Countershaft Rear Bearing Thrust Washer
Courtesy of FORD MOTOR CO.
Remove the reverse idler shaft bolt.

Fig 9: Locating Reverse Idler Shaft Bolt
Courtesy of FORD MOTOR CO.
Remove the reverse idler gear and bushing.

Fig 10: Locating Reverse Idler Gear & Bushing
Courtesy of FORD MOTOR CO.
Using the special tools, remove the output shaft rear bearing.

Fig 11: Identifying Special Output Shaft Rear Bearing Removal Tools
Courtesy of FORD MOTOR CO.
Remove the output shaft reverse gear.

Fig 12: Removing Output Shaft Reverse Gear
Courtesy of FORD MOTOR CO.
Remove the spacer.

Fig 13: Locating Spacer
Courtesy of FORD MOTOR CO.
Remove the countershaft reverse gear, the 2 countershaft reverse gear needle bearings, and the reverse synchronizer blocking ring.

Fig 14: Locating Countershaft Reverse Gear, Countershaft Reverse Gear Needle Bearings & Reverse Synchronizer Blocking Ring
Courtesy of FORD MOTOR CO.
Remove the thrust washer.

Fig 15: Locating Thrust Washer
Courtesy of FORD MOTOR CO.
Remove the countershaft split washer.

Fig 16: Locating Countershaft Split Washer
Courtesy of FORD MOTOR CO.
Remove the 5th/reverse gear shift rail bolt.

Fig 17: Locating 5th/Reverse Gear Shift Rail Bolt
Courtesy of FORD MOTOR CO.
Remove the 5th/reverse synchronizer, the gear shifter fork and the reverse gear shift rail as an assembly.

Fig 18: Removing Fifth/Reverse Synchronizer, Gear Shifter Fork & Reverse Gear Shift Rail
Courtesy of FORD MOTOR CO.
Remove the countershaft 5th gear synchronizer blocking ring.

Fig 19: Locating Countershaft 5th Gear Synchronizer Blocking Ring
Courtesy of FORD MOTOR CO.
Remove the 5th/reverse shift lever bolt and the nut, then remove the plate.

Fig 20: Locating 5th/Reverse Shift Lever Bolt & Nut
Courtesy of FORD MOTOR CO.
Remove the 5th/reverse shift lever.

Fig 21: Removing 5th/Reverse Shift Lever
Courtesy of FORD MOTOR CO.
- Slide the 5th/reverse shift lever and shaft assembly from the case.
Remove the countershaft 5th gear.

Fig 22: Locating Countershaft 5th Gear
Courtesy of FORD MOTOR CO.
Remove the countershaft 5th gear split bearing and the race.

Fig 23: Locating Countershaft Fifth Gear Split Bearing & Race
Courtesy of FORD MOTOR CO.
Remove the locking ball.
Remove the output shaft 5th gear.

Fig 24: Locating Output Shaft 5th Gear
Courtesy of FORD MOTOR CO.
Remove the rear bearing retainer.

Fig 25: Identifying Rear Bearing Retainer
Courtesy of FORD MOTOR CO.
- Remove the retainer bolts.
- Remove the bearing retainer.
Remove the clutch slave cylinder. For additional information, refer to CLUTCH CONTROLS article.
Remove the bolts.

Fig 26: Locating Bolts
Courtesy of FORD MOTOR CO.
Remove the main drive gear bearing retainer.

Fig 27: Identifying Main Drive Gear Bearing Retainer Bolts
Courtesy of FORD MOTOR CO.
- Install the Front Cover Remover into the clutch slave cylinder bolt locations.
  - Alternately tighten the bolts until the bearing retainer can be removed by hand.
- Remove the main drive gear bearing retainer.
Remove the fluid baffle, the input bearing shim and the countershaft bearing shim.

Fig 28: Locating Fluid Baffle, Input Bearing Shim & Countershaft Bearing Shim
Courtesy of FORD MOTOR CO.
Remove the front oil passage bolt.

Fig 29: Locating Front Oil Passage Bolt
Courtesy of FORD MOTOR CO.
Remove the oil passage.

Fig 30: Locating Oil Passage
Courtesy of FORD MOTOR CO.
Remove the input shaft front bearing race.

Fig 31: Locating Input Shaft Front Bearing Race
Courtesy of FORD MOTOR CO.
Remove the output shaft center bearing race.

Fig 32: Locating Output Shaft Center Bearing Race
Courtesy of FORD MOTOR CO.
Separate the input shaft from the output shaft.

Fig 33: Removing Input Shaft From Output Shaft
Courtesy of FORD MOTOR CO.
Remove the output shaft.

Fig 34: Locating Output Shaft
Courtesy of FORD MOTOR CO.
Remove the input shaft and bearing.

Fig 35: Locating Input Shaft & Bearing
Courtesy of FORD MOTOR CO.
Remove the countershaft cluster gear.

Fig 36: Locating Countershaft Cluster Gear
Courtesy of FORD MOTOR CO.

Fig 37: Inspecting Countershaft For Damage

Courtesy of FORD MOTOR CO.

Inspect the countershaft for wear or damage. Install a new countershaft as necessary.