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Section 122 (Manual Transaxle/Transmission - Mt82 GETRAG 6-Speed): Assembly: Transmission

WARNING: This page is about a different car, the 2013 Ford Mustang. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOLS

G07488802
 Holding Tool, Drive Pinion Flange
205-478
G07488803
 Holding Tool, Rear Flange
308-807
G07488804
 Installer, Front Seal
308-806
G07488608
 Installer, Rear Flange
308-808
G07488609
 Installer, Rear Seal
308-811
G07488607
 Installer, Synchro Gear Pack
308-809
MATERIAL SPECIFICATIONS

Item Specification
Motorcraft® Gasket Maker
TA-16		 WSK-M2G348-A5
Motorcraft® Dual Clutch Transmission Fluid
XT-11-QDC		 WSS-M2C200-D2
Motorcraft® Threadlock 262
TA-26		 WSK-M2G351-A6
Motorcraft® Threadlock and Sealer
TA-25		 WSK-M2G351-A5
G07488808
Item Part Number Description
1 --- Clutch slave cylinder bolt (2 required)
2 7A508 Clutch slave cylinder
3 7048 Input shaft seal
4 7A010 Countershaft bolt cover
5 7L013 Countershaft bolt
6 7064 Input shaft snap ring
7 --- Front transmission case assembly
8 7A443 Shift fork pivot bolts (6 required)
9 W714875 Output Shaft Speed (OSS) sensor bolt
10 7H103 OSS sensor
11 7M131 Shift rail detents (4 required)
12 7K341 Transmission case vent tube
13 7C031 Shift shaft stop pin
14 7L027 Magnet
15 7017 Input shaft
16 7C043 Output shaft roller bearing
17 7M000 5th gear synchronizer cone
18 7107 5th gear synchronizer ring
19 - Countershaft assembly
20 7230 3rd/4th shift fork
21 7241 3rd/4th shift rail
22 - Output shaft assembly
23 7230 5th/6th shift fork
24 7242 5th/6th shift rail
25 7025 Center support bearing (output shaft)
26 7025 Center support bearing (countershaft)
27 7J086 Center support
28 7234 Spring
29 7K024 Dowels (2 required)
30 7J172 Spacers (2 required)
31 7K201 Interlock plate
32 W715104 Center support bolts (3 required)
33 7A443 Interlock plate bolts (2 required)
34 7M037 2nd gear needle bearing
35 7102 2nd gear
36 7107 2nd gear synchronizer ring assembly
37 7210 Shift shaft assembly
38 7124 1st/2nd gear synchronizer assembly
39 7230 1st/2nd shift fork
40 7C031 Roll pin
41 7240 1st/2nd shift rail
42 7107 1st gear synchronizer ring assembly
43 7064 1st/2nd gear synchronizer assembly snap ring
44 7M037 1st gear needle bearing
45 7100 1st gear
46 7N168 Reverse gear needle bearing race
47 7M037 Reverse gear needle bearing
48 7C238 Reverse gear
49 7107 Reverse gear synchronizer ring
50 7124 Reverse gear synchronizer assembly
51 7230 Reverse shift fork
52 7241 Reverse shift rail
53 - Rear transmission case assembly
54 W714875 Skip shift solenoid bolts (2 required) (if equipped)
55 7G136 Skip shift solenoid (if equipped)
56 7C031 Skip shift solenoid pin (if equipped)
57 7234 Skip shift solenoid spring (if equipped)
58 15520 Reverse lamp switch
59 W715103 Transmission case bolts
60 7052 Output shaft seal
61 7K177 Output shaft flange
62 7L013 Output shaft flange bolt
NOTE: Lubricate all components with the recommended transmission fluid before assembling.
  1. NOTE: Do not heat the input shaft bearing higher than 120°C (248°F) maximum or damage to the input shaft bearing can occur.

    Using a suitable heat gun, heat the input shaft bearing inner race to a maximum of 120°C (248°F).

    G07488809
  2. With the oil feed hole facing the countershaft bearing, install the input shaft.
    G07488810
  3. Install the input shaft snap ring.
    G07488730
  4. NOTE: Make sure the small diameter side of the output shaft roller bearing cage is facing the input shaft or damage to the output shaft bearing can occur.

    With the small diameter side of the output shaft roller bearing cage facing the input shaft, install the output shaft roller bearing.

    G07488812
  5. NOTE: Apply petroleum jelly to hold the 5th gear synchronizer ring and the 5th gear synchronizer cone in place during assembly.

    Install the 5th gear synchronizer ring and the 5th gear synchronizer cone.

    G07488813
  6. Assemble the shafts with the oil feed hole on the 5th gear cone facing the countershaft.
    G07488814
  7. NOTE: Do not heat the countershaft bearing higher than 120°C (248°F) maximum or damage to the countershaft bearing can occur.

    Using a suitable heat gun, heat the countershaft bearing inner race to a maximum of 120°C (248°F).

    G07488815
  8. With the oil feed holes aligned, install the output shaft and countershaft assembly.
    G07488816
  9. NOTE: Make sure the shift fork pivot bolts engage into the shift fork or damage to the shift fork can occur.

    Install the 5th/6th shift fork, the 5th/6th shift rail and loosely install the shift fork pivot bolts.

    • Apply Threadlock and Sealer to the shift fork pivot bolts.
      G07488817
  10. NOTE: Make sure the shift fork pivot bolts engage into the shift fork or damage to the shift fork can occur.

    Install the 3rd/4th shift fork, the 3rd/4th shift rail and loosely install the shift fork pivot bolts.

    • Apply Threadlock and Sealer to the shift fork pivot bolts.
      G07488818
  11. Tighten the 2 LH and the 2 RH shift fork pivot bolts.
    • Tighten to 37 Nm (27 lb-ft).
      G07488819
  12. Push down the 3rd/4th shift rail and the 5th/6th shift rail to lock the transmission into 2 gears.
    G07488820
  13. NOTE: When installing the bearings, do not over expand the bearing cages or damage to the bearing cages can occur.

    Slightly expand the center support bearing cages and slide the center support bearings down the shaft assemblies. Lock the bearing cage tabs.

    G07488725
  14. Loosely install the center support and tighten the 3 center support bolts fingertight.
    G07488824
  15. NOTE: Install the counter shaft bolt with the transmission in the vertical position with the input shaft facing down.

    Install the countershaft bolt.

    • Apply Threadlock 262 to the countershaft bolt.
    • Tighten to 95 Nm (70 lb-ft).
      G07488697
  16. Remove the center support and 3 center support bolts.
    G07488824
  17. Pull up on the 3rd/4th shift rail and the 5th/6th shift rail to unlock the transmission from 2 gears.
    G07488822
  18. NOTE: The center support must be tightened evenly or damage to the center support or transmission case can occur.

    Install the center support and evenly tighten the 3 center support bolts.

    • Apply Threadlock 262 to the 3 center support bolts.
    • Tighten to 24 Nm (18 lb-ft).
      G07488824
  19. Install the spring and spacers.
    G07488825
  20. NOTE: Make sure the interlock plate moves freely.

    Install the interlock plate and the 2 interlock plate bolts.

    • Apply Threadlock 262 to the 2 interlock plate bolts.
    • Tighten to 24 Nm (18 lb-ft).
      G07488826
  21. Install the 2nd gear needle bearing.
    G07488827
  22. Install the 2nd gear.
    G07488828
  23. NOTE: The 6 synchronizer ring tabs must engage into the 6 gear slots or damage to the synchronizer ring assembly can occur.
    NOTE: The 2nd gear synchronizer ring assembly outer ring has 2 identification notches.

    Install the 2nd gear synchronizer ring assembly.

    G07488829
  24. NOTE: The 3 synchronizer ring tabs must engage into the 3 synchronizer hub slots or damage to the synchronizer hub and the synchronizer ring assembly can occur.
    NOTE: The long shoulder of the 1st/2nd synchronizer hub must be facing 2nd gear or damage to the synchronizer hub can occur.

    With the long shoulder of the 1st/2nd synchronizer hub facing 2nd gear, use the Synchro Gear Pack Installer and install the 1st/2nd synchronizer hub.

    G07488830
  25. Install the 1st/2nd synchronizer hub snap ring.
    G07488831
  26. NOTE: Align the index marks made during removal on the synchronizer sleeve and the synchronizer hub.

    With the groove on the 1st/2nd synchronizer sleeve facing 2nd gear, install the 1st/2nd shift fork the 1st/2nd shift rail and the 1st/2nd synchronizer sleeve.

    G07488716
  27. NOTE: Slide the synchronizer sleeve up to install the pressure pieces.

    Install the 3 pressure pieces.

    G07488715
  28. NOTE: The 3 synchronizer ring tabs must engage into the 3 synchronizer assembly slots or damage to the synchronizer assembly and the synchronizer ring assembly can occur.
    NOTE: The 1st gear synchronizer ring assembly outer ring has one identification notch.

    Install the 1st gear synchronizer ring assembly.

    G07488834
  29. Install the 1st gear needle bearing.
    G07488835
  30. NOTE: The 6 synchronizer ring tabs must engage into the 6 gear slots or damage to the synchronizer assembly and synchronizer ring assembly can occur.

    Install the 1st gear.

    G07488836
  31. Using the Synchro Gear Pack Installer, install the reverse gear needle bearing race.
    G08645207
  32. Install the reverse gear needle bearing.
    G07488838
  33. Install the reverse gear.
    G07488839
  34. NOTE: The shift shaft must be installed in the neutral position prior to installing the shift shaft stop pin or damage to the shift shaft stop pin can occur.

    Install the shift shaft in the neutral position, using a soft-faced hammer install the shift shaft stop pin.

    G07488840
  35. Install the reverse gear synchronizer ring.
    G07488841
  36. NOTE: The 3 synchronizer ring tabs must engage into the 3 synchronizer assembly slots or damage to the synchronizer assembly and the synchronizer ring can occur.

    Using the Synchro Gear Pack Installer, install the reverse gear synchronizer assembly.

    G07488842
  37. NOTE: To install the reverse shift fork and the reverse shift rail assembly, the transmission must be in neutral and the groves on the shift rails must be aligned with the interlock plate.

    Install the reverse shift fork and the reverse shift rail assembly.

    G07488709
  38. Install the magnet.
    G07488717
  39. Shift the transmission into 4th gear.
    G07488845
  40. NOTE: Do not wait longer than 10 minutes to install the rear transmission case assembly due to the rapid cure time of the sealant.

    Clean the sealing surfaces of the front transmission case and the sealing surfaces of the rear transmission case. Thinly coat the sealing surface of the front transmission case assembly and the sealing surface of the rear transmission case assembly with Gasket Maker.

  41. NOTE: The rear transmission case assembly must be installed evenly with the transmission shifted into 4th gear, do not allow the shift rails to bind during installation or damage to the transmission case assembly can occur.

    Using the Synchro Gear Pack Installer and the Rear Flange Installer, install the rear transmission case assembly.

    G07488846
  42. NOTE: Make sure the shift fork pivot bolts engage into the shift fork or damage to the shift fork can occur.

    Install the 2 shift fork pivot bolts.

    • Apply Threadlock and Sealer to the shift fork pivot bolts.
    • Tighten to 37 Nm (27 lb-ft).
      G07488847
  43. Loosely install the 15 transmission case bolts.
    G07488848
  44. Using a suitable brass drift, tap the 2 dowel pins flush with the transmission case.
    G07488849
  45. Tighten the 15 transmission case bolts.
    • Tighten to 24 Nm (18 lb-ft).
      G07488850
  46. Using a soft-faced hammer install the 4 shift rail detents.
    G07488851
  47. If equipped, install the skip shift solenoid pin and spring.
    G07488704
  48. If equipped, seat the skip shift solenoid into the transmission case and hold, while securing the 2 skip shift solenoid bolts.
    • Tighten to 10 Nm (89 lb-in).
      G07488703
  49. Install the reverse lamp switch.
    1. Install the reverse lamp switch.
      • Tighten to 20 Nm (177 lb-in).
    2. Attach the electrical connector retainer.
      G07990924
  50. Install the Output Shaft Speed (OSS) sensor and the OSS sensor bolt.
    • Tighten to 10 Nm (89 lb-in).
      G07488701
  51. Install a new output shaft seal on the Rear Seal Installer and Handle.
    G07488619
  52. Using the Rear Seal Installer and the Handle, install the output shaft seal.
    G07488857
  53. Using the Synchro Gear Pack Installer and the Rear Flange Installer, install the output shaft flange.
    G07488858
  54. Install the Drive Pinion Flange Holding Tool and the Rear Flange Holding Tool on the output shaft flange. Clean the threads on the output shaft bolt and apply one dot of Threadlock 262 to the lower end of the output shaft bolt threads. Using the Drive Pinion Flange Holding Tool and the Rear Flange Holding Tool, install the output shaft flange bolt. Tighten the output shaft flange bolt in 3 stages.
    • Stage 1: Tighten to 200 Nm (148 lb-ft).
    • Stage 2: Loosen the output shaft flange bolt.
    • Stage 3: Tighten to 180 Nm (133 lb-ft).
      G07488698
  55. Using the Rear Seal Installer and the Handle, install the countershaft bolt cover.
    G07488860
  56. Using the Front Seal Installer, install the new input shaft seal.
    G07488861
  57. Install the clutch slave cylinder and if equipped, the clutch slave cylinder spacer.
    1. Position the clutch slave cylinder and if equipped, the clutch slave cylinder spacer and connect the tube in the retaining clip.
    2. Install the 2 clutch slave cylinder bolts.
      • Tighten to 11 Nm (97 lb-in).
        G07488862
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