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Transmission Gear Assemblies - Disassembled View

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Fig 1: Exploded View Of Transmission Gear Assemblies
G08645448Courtesy of FORD MOTOR CO.
Item Part Number Description
1 7L172 Shim
2 7025 Input shaft bearing/race
3 7017 Input shaft
4 7025 Cylindrical roller bearing
5 7025 Axial thrust bearing
6 7025 Axial thrust washer
7 7A082 Snap ring
8 - 4th gear synchronizer ring assembly
9 7124 3rd/4th synchronizer assembly
10 7107 3rd synchronizer ring assembly
11 7117 Spacer
12 7M037 3rd gear needle bearing
13 7B340 3rd gear
14 7061 Output shaft
15 7M037 2nd gear needle bearing
16 7102 2nd gear
17 7117 Spacer
18 7107B 2nd gear synchronizer ring assembly
19 7124A 1st/2nd synchronizer assembly
20 7107A 1st gear synchronizer ring assembly
21 7A082A Split ring
22 7A082A Retainer
23 7025 1st gear needle bearing
24 7100 1st gear
25 7025 Output shaft rear bearing/race
26 7L047 6th driven gear
27 7K316 5th driven gear
28 7A082 Retainer
29 7A082 Split ring
30 - Synchronizer cone (part of 7107)
31 7124B Reverse synchronizer assembly
32 7A082 Snap ring
33 7107C Reverse gear synchronizer ring assembly
34 7C238 Reverse gear
35 7025 Reverse gear needle bearing
36 7A385 Thrust washer
37 7A082 Snap ring
38 7A082 Spacer
39 7025 Rear output shaft bearing
40 7A082 Spacer
41 7A082 Snap ring
42 7E172 Check ball
43 7H150 OSS sensor tone wheel
44 7A082 Snap ring
45 7L172 Shim
46 7025 Countershaft front bearing/race
47 7113 Countershaft
48 7025 Countershaft rear bearing/race
49 7119 Thrust washer
50 7117 Spacer
51 7146 6th gear
52 7025 6th gear needle bearing
53 7107 6th gear synchronizer ring assembly
54 7124 5th/6th synchronizer assembly
55 7107 5th gear synchronizer ring assembly
56 7117 Spacer
57 7A082 Snap ring
58 7144 5th gear
59 7025 5th gear needle bearing
60 7025 Thrust washer
61 7A082 Snap ring
62 - Reverse driver gear
63 7A082 Snap ring
64 7C211 Reverse idler shroud bracket bolt
65 7723 Reverse idler shaft bracket
66 7141 Reverse idler gear
67 7025 Reverse idler gear needle bearing
68 7140 Reverse idler gear shaft
  1. Lubricate all components with clean transmission fluid during assembly.
  2. Attach the transmission clutch housing to the Transmission Holding Fixture.
    Fig 2: Connecting Transmission Clutch Housing To Transmission Holding Fixture
    G06384435Courtesy of FORD MOTOR CO.
  3. NOTE: If a new front input shaft bearing or front countershaft bearing was installed, install the new bearing cups.

    Install the input shaft bearing cup and the countershaft bearing cup. Do not install the shims at this time.

    G08645450
  4. Install the input shaft, the cylindrical roller bearing, the axial thrust bearing and the 4th gear synchronizer ring assembly.
    • Align the synchronizer ring tabs with the gear slots.
      G08645451
  5. Install the output shaft onto the input shaft.
    • Align the synchronizer ring tabs with the synchronizer hub slots.
  6. NOTE: Make sure the countershaft seats into the oil pump drive or damage to the oil pump or transmission case can occur.

    Align the oil pump drive with the countershaft and install the countershaft.

    • Lift the output shaft upward, tilt the countershaft and install.
      G06384436
  7. Install the transmission main case-to-clutch housing gasket and the transmission main case.
    G08645453
  8. Install the 11 transmission main case-to-clutch housing bolts.
    • Tighten the bolts in a star pattern to 48 Nm (35 lb-ft).
      G08645454
  9. NOTE: The input shaft/output shaft end play must be measured with a gasket installed between the clutch housing and the transmission main case or incorrect end play will occur.
    NOTE: Rotate the input shaft/output shaft to seat the bearings.

    Using the Dial Indicator Gauge with Holding Fixture and the Clutch Housing Gauge, measure the input shaft/output shaft end play by applying an upward load on the input shaft. Record the measurement.

    Fig 3: Measuring Input Shaft/Output Shaft End Play
    G06384438Courtesy of FORD MOTOR CO.
  10. NOTE: The countershaft shaft end play must be measured with a gasket installed between the clutch housing and the transmission main case or incorrect end play will occur.
    NOTE: Rotate the countershaft to seat the bearings.

    Using the Dial Indicator Gauge with Holding Fixture and the Clutch Housing Gauge, measure the countershaft gear end play by pulling upward on the countershaft. Record the measurement.

    Fig 4: Measuring Countershaft Gear End Play
    G06384439Courtesy of FORD MOTOR CO.
  11. Remove the 11 transmission main case-to-clutch housing bolts, the transmission main case and the gasket.
    G08645454
  12. Remove the countershaft and output shaft.
    Fig 5: Locating Countershaft And Output Shaft
    G08645458Courtesy of FORD MOTOR CO.
  13. Remove the input shaft assembly.
    G08645451
  14. Remove the input shaft bearing cup and the countershaft bearing cup.
    G08645450
  15. Using the Input Shaft Oil Seal Installer with Handle, install the new input shaft seal.
    Fig 6: Installing Input Shaft Seal Using Input Shaft Oil Seal Installer And Handle
    G06384442Courtesy of FORD MOTOR CO.
  16. Using the recorded end play measurements, select and install the appropriate shims to achieve the correct end play. Input shaft, output shaft and countershaft endplay specification is 0.0127-0.0889 mm (0.0005-0.0035 in).
    G08645462
  17. Install the input shaft bearing cup and the countershaft bearing cup.
    • Lubricate the bearing cups with petroleum jelly.
      G08645353
  18. Install the input shaft, the cylindrical roller bearing, the axial thrust bearing and the 4th gear synchronizer ring assembly.
    • Align the synchronizer ring tabs with the gear slots.
      G08645451
  19. Assemble the shift rail assembly to the output shaft, then install the output shaft and shift rail as an assembly.
    • Align the 4th gear synchronizer ring tabs with the 4th gear synchronizer hub slots.
      G08645465
  20. NOTE: Make sure the countershaft seats into the oil pump drive or damage to the oil pump or transmission case can occur.

    Align the oil pump drive with the countershaft and install the countershaft.

    • Lift the output shaft upward, tilt the countershaft and install.
      G08645466
  21. Install the 6th gear spacer and thrust washer.
    Fig 7: Locating 6th Gear Spacer And Thrust Washer
    G06384356Courtesy 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.
    Fig 8: Locating 5th/6th And Reverse Shift Rail Assembly
    G07991142Courtesy of FORD MOTOR CO.
  23. Install the shift detent, the shift detent spring and the shift detent plug.
    • Apply thread sealant to the threads of the shift detent plug.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 9: Locating Shift Lever Detent Plug
      G06384355Courtesy of FORD MOTOR CO.
  24. Install the oil pump pickup tube.
    G08645470
  25. Install the new transmission main case-to-clutch housing gasket.
    G08645346
  26. 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.
      G08645472
  27. Install the 11 transmission main case-to-clutch housing bolts.
    • Tighten the bolts in a star pattern to 48 Nm (35 lb-ft).
      G08645454
  28. Apply threadlock and sealer to the threads of the shift lever guide bolts, then install the bolts.
    • Pull up on the 5th/6th shift rail to align the slot of the interlock plate with the guide bolt hole.
    • Tighten to 27 Nm (20 lb-ft).
      Fig 10: Locating Shift Lever Guide Bolts
      G06384354Courtesy of FORD MOTOR CO.
  29. Install a new front offset lever roll pin.
    • Install the roll pin flush with the offset lever.
      G08645475
  30. Install the 6th gear needle bearing and 6th gear.
    • Apply petroleum jelly to the needle bearing.
      G08645341
  31. Install the 6th gear synchronizer ring assembly.
    • Align the synchronizer ring tabs with the gear slots.
      Fig 11: Locating 6th Gear Synchronizer Ring Assembly
      G06384351Courtesy of FORD MOTOR CO.
  32. Using the Bearing Tube Remover/Installer and a soft faced hammer, install the 5th/6th gear synchronizer hub.
    • Align the synchronizer ring tabs with the synchronizer hub slots.
      G08645478
  33. NOTE: Slide the synchronizer sleeve down while installing the pressure pieces.

    Install the 5th/6th gear shift fork, the 5th/6th gear synchronizer sleeve and the 3 pressure pieces as an assembly.

    Fig 12: Locating 5th/6th Gear Shift Fork
    G06384349Courtesy of FORD MOTOR CO.
  34. Install the new 5th/6th shift fork snap ring.
    Fig 13: Locating 5th/6th Shift Fork Snap Ring
    G06384342Courtesy of FORD MOTOR CO.
  35. Install a new snap ring on the countershaft.
    Fig 14: Locating Countershaft Snap Ring
    G06384348Courtesy of FORD MOTOR CO.
  36. Install the 5th gear synchronizer ring assembly.
    • Align the synchronizer ring tabs with the synchronizer hub slots.
      Fig 15: Locating 5th Gear Synchronizer Ring Assembly
      G06384347Courtesy of FORD MOTOR CO.
  37. Install the spacer and the 5th drive gear needle bearing.
    • Apply petroleum jelly to the needle bearing.
      Fig 16: Locating 5th Drive Gear Needle Bearing And Spacer
      G06384346Courtesy of FORD MOTOR CO.
  38. Install the following components:
    1. The 5th drive gear.
      • Align the synchronizer ring tabs with the gear slots.
    2. The 5th drive gear thrust washer.
    3. 3 A new 5th drive gear snap ring.
      Fig 17: Identifying 5th Drive Gear, Thrust Washer And Snap Ring
      G08645484Courtesy of FORD MOTOR CO.
  39. Using the Bearing Tube Remover/Installer and a soft faced hammer, install the reverse drive gear.
    G08645485
  40. Install a new reverse drive gear snap ring.
    Fig 18: Locating Reverse Drive Gear Snap Ring
    G06384343Courtesy of FORD MOTOR CO.
  41. Using the Bearing Tube Remover/Installer and a soft faced hammer, position the 5th driven gear onto the second set of the output shaft splines.
    G08645487
  42. NOTE: Align the gear teeth of the 5th driven gear with the gear teeth of the 5th drive gear on the countershaft.

    Using the Bearing Tube Remover/Installer, the Halfshaft Installer and the Transmission Extension Housing Bushing Installer, install the 5th driven gear in 2 stages:

    • Stage 1: Using the Bearing Tube Remover/Installer and the Halfshaft Installer, press the 5th driven gear down to align with the countershaft 5th drive gear.
    • Stage 2: Using the Bearing Tube Remover/Installer, the Halfshaft Installer and the Transmission Extension Housing Bushing Installer, press the 5th driven gear down to seat on the 6th driven gear.
      G08645488
  43. Install the split ring and retainer.
    Fig 19: Locating Split Ring And Retainer
    G06384458Courtesy of FORD MOTOR CO.
  44. Using the Bearing Tube Remover/Installer and a soft faced hammer, install the reverse gear synchronizer hub.
    • Align the synchronizer ring tabs with the synchronizer hub slots.
      G08645490
  45. NOTE: Slide the synchronizer sleeve down while installing the pressure pieces.

    Install the reverse shift fork, the reverse synchronizer sleeve and the 3 pressure pieces as an assembly.

    Fig 20: Locating Reverse Shift Fork
    G06384338Courtesy of FORD MOTOR CO.
  46. Install a new reverse shift fork snap ring.
    Fig 21: Locating Reverse Shift Fork Snap Ring
    G06384337Courtesy of FORD MOTOR CO.
  47. Install a new reverse gear synchronizer snap ring.
    Fig 22: Locating Reverse Gear Synchronizer Snap Ring
    G06384336Courtesy of FORD MOTOR CO.
  48. Install the reverse gear synchronizer rings assembly.
    • Align the synchronizer ring tabs with the synchronizer hub slots.
      Fig 23: Locating Reverse Gear Synchronizer Blocking Rings
      G06384335Courtesy of FORD MOTOR CO.
  49. Install the reverse gear needle bearing.
    • Apply petroleum jelly to the needle bearing.
      Fig 24: Locating Reverse Gear Needle Bearing
      G06384334Courtesy of FORD MOTOR CO.
  50. Install the reverse gear.
    • Align the synchronizer ring tabs with the gear slots.
      Fig 25: Locating Reverse Gear
      G06384463Courtesy of FORD MOTOR CO.
  51. Install the reverse gear thrust washer.
    Fig 26: Locating Reverse Gear Thrust Washer
    G06384464Courtesy of FORD MOTOR CO.
  52. Install a new reverse gear snap ring.
    Fig 27: Locating Reverse Gear Snap Ring
    G06384465Courtesy of FORD MOTOR CO.
  53. Install the lower spacer, the rear output shaft roller bearing and the upper spacer.
    Fig 28: Rear Output Shaft Roller Bearing, Upper And Lower Spacer
    G06384466Courtesy of FORD MOTOR CO.
  54. Install a new rear output shaft roller bearing snap ring.
    Fig 29: Locating Rear Output Shaft Roller Bearing Snap Ring
    G06384467Courtesy of FORD MOTOR CO.
  55. Position the check ball on the output shaft. Install the OSS sensor tone wheel.
    Fig 30: Locating OSS Sensor Tone Wheel And Check Ball On Output Shaft
    G06384330Courtesy of FORD MOTOR CO.
  56. Install a new OSS sensor tone wheel snap ring.
    G08645318
  57. Install the reverse shift rail, then install a new roll pin.
    • Install the roll pin until it is flush with the lever.
      G08645503
  58. Install the bearing spacer and the race.
    Fig 31: Locating Bearing Spacer And Race
    G06384468Courtesy of FORD MOTOR CO.
  59. Install the new extension housing gasket.
    G08645316
  60. NOTE: Install the transmission identification tag in the location noted during removal.
    NOTE: Apply thread sealant to the threads of the 2 top extension housing bolts.

    Install the extension housing and the 8 extension housing bolts.

    • Tighten to 48 Nm (35 lb-ft).
      G08645315
  61. Install the new shift detent cover gasket.
    G08645314
  62. Install the shift detent cover and the 4 shift detent cover bolts.
    • Tighten to 20 Nm (177 lb-in).
      Fig 32: Locating Shift Detent Cover Bolts
      G06384327Courtesy of FORD MOTOR CO.
  63. Install the output shaft flange and a new internal o-ring. 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).
      G08645509
  64. Install the clutch slave cylinder and the 2 clutch slave cylinder bolts.
    • Tighten to 12 Nm (106 lb-in).
      G08645310
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