Section 385 (Manual Transmission - 6-Speed Manual Transmission - B6 (Except Electric Vehicle)): Installation: Transmission

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	205-115A (205-115) Installer, Drive Pinion Seal
Ford Diagnostic Equipment
Transmission Jack
Cable Ties
Retaining Strap
Wooden Block

Materials 

• 1.
  
  Apply a thin coating of grease.

  Material: High Temperature 4x4 Front Axle and Wheel Bearing Grease / XG-11 (WSS-M1C267-A1)

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• 2.
  
  Install the following items:
  • Use the General Equipment: Transmission Jack
  • Use the General Equipment: Wooden Block
  • Use the General Equipment: Retaining Strap

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• 3.
  
  Install the transmission onto the engine.

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• 4.
  
  Install the bellhousing bolt.

  Torque: 35 lb.ft (48 Nm)

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• 5.
  
  Install the bellhousing bolt.

  Torque: 35 lb.ft (48 Nm)

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• 6.
  
  Install the transmission support insulator bracket.

  Torque: 59 lb.ft (80 Nm)

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• 7.
  
  Install the transmission support insulator.

  Torque: 109 lb.ft (148 Nm)

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• 8.
  
  Install the lower bellhousing bolts.

  Torque: 35 lb.ft (48 Nm)

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• 9.
  
  Install the exhaust support bracket.

  Torque: 18 lb.ft (25 Nm)

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• 10.
  
  Install the exhaust insulator.

  Torque: 19 lb.ft (26 Nm)

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• 11.
  
  
  NOTE: Make sure that the exhaust flexible pipe is not forcibly bent or twisted.

  Apply a thin coating of anti-seize and install the exhaust pipe on the flexpipe.

  Material: Bostik Never-Seez Regular Grade (nickel free) Anti-Seize and Lubricating Compound / Purchase locally

  Torque: 35 lb.ft (48 Nm)

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• 12.
  
  Remove the cable ties. Use the General Equipment: Cable Ties

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• 13.
  
  Position the starter back and install the bolts.

  Torque: 26 lb.ft (35 Nm)

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• 14.
  
  
  NOTE: If the transmission has been replaced or overhauled, the seals do not need to be replaced.

  Remove and discard the RH halfshaft seal.

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• 15.
  
  Using the special tool, install a new RH halfshaft seal. Use Special Service Tool: 205-115A (205-115) Installer, Drive Pinion Seal.

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• 16.
  
  
  NOTE: Do not fully install the halfshaft at this time.

  Using part: 97ZT-7M181-A Seal Protector, slide the RH halfshaft into the transmission until the splines are past the seal and remove the seal protector.

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• 17.
  
  Insert the RH halfshaft until the intermediate shaft bearing is centered in the concave groove of the intermediate shaft bearing bracket.

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• 18.
  
  Install the halfshaft retaining strap.

  Torque:

  Stage 1: Lower nut:: 44 lb.in (5 Nm)

  Stage 2: Upper nut:: 18 lb.ft (25 Nm)

  Stage 3: Lower nut:: 18 lb.ft (25 Nm)

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• 19.
  
  Install the RH lower control arm in the knuckle.

  Torque: 61 lb.ft (83 Nm)

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• 20.
  
  Install the RH brake hose on the strut.

  Torque: 89 lb.in (10 Nm)

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• 21.
  
  Install the LH halfshaft. Refer to: Front Halfshaft LH .

• 22.
  
  Install both front wheels and tires. Refer to: Wheel and Tire .

• 23.
  
  Install the roll restrictor and bracket.

  Torque:

  1: 52 lb.ft (70 Nm)

  2: 92 lb.ft (125 Nm)

  3: 92 lb.ft (125 Nm)

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• 24.
  
  Install the 2 top bellhousing bolts and the top starter motor bolt.

  Torque: 35 lb.ft (48 Nm)

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• 25.
  
  Connect the wiring harness retainer on the back of the transmission.

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• 26.
  
  Connect the slave cylinder hydraulic tube to the slave cylinder.

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• 27.
  
  Connect the neutral position sensor.

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• 28.
  
  Install the shift cable bracket.

  Torque: 18 lb.ft (25 Nm)

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• 29.
  
  Connect the shift cables, connect the slave cylinder hydraulic tube to the bracket and connect the reverse light switch.

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• 30.
  
  Adjust the shift cables. Refer to: Gearshift Cable Adjustment - 6-Speed Manual Transmission - B6 .

• 31.
  
  Install the battery tray support bracket.

  Torque: 35 lb.ft (48 Nm)

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• 32.
  
  Install the battery tray. Refer to: Battery Tray .

• 33.
  
  Install the air cleaner. Refer to: Air Cleaner .

• 34.
  
  Fill the transmission. Refer to: Transmission Draining and Filling .

• 35.
  
  Bleed the clutch hydraulic system. Refer to: Clutch System Bleeding - 6-Speed Manual Transmission - B6 .

• 36.
  
  Install the underbody shield.

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• 37.
  
  After completing the repairs, perform the Misfire Monitor Neutral Profile Correction procedure. Use the General Equipment: Ford Diagnostic Equipment