Transmission - Mexico

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	205-075Installer, Rear Wheel Hub Seal
Courtesy of FORD MOTOR COMPANY	205-115A (205-115)Installer, Drive Pinion Seal
Courtesy of FORD MOTOR COMPANY	205-153 (T80T-4000-W)Handle
Courtesy of FORD MOTOR COMPANY	205-479Installer, Drive Pinion FlangeTKIT-2000AP-FLM/LMTKIT-2002-F/FM
Courtesy of FORD MOTOR COMPANY	307-003 (T57L-500-B)Holding Fixture, Transmission
Courtesy of FORD MOTOR COMPANY	307-557Installer, Ball BearingTKIT-2005U-FLMTKIT-2005U-LMTKIT-2006U-FLM/LMTKIT-2006UF/FM
Courtesy of FORD MOTOR COMPANY	307-674Installer, Outer Input SealTKIT-2010D-FLMTKIT-2010D-ROW
Courtesy of FORD MOTOR COMPANY	308-710Installer, Bearing Cup
Courtesy of FORD MOTOR COMPANY	308-847Installer, Inputshaft Seal
Courtesy of FORD MOTOR COMPANY	308-880Installer, Driveshaft Seal
Hydraulic Press
Punch

Materials 

Name	Specification
Motorcraft ® Silicone Gasket and SealantTA-30	WSE-M4G323-A4
Motorcraft ® Gasket MakerTA-16	WSK-M2G348-A5

1. Differential Pinion Gear - Assembly	multimedia:A supplement to the article is available.
2. Differential Ring Gear - Assembly	multimedia:A supplement to the article is available.
3. Tone Ring and Differential Bearings - Assembly	multimedia:A supplement to the article is available.
4. Input Shaft Bearing - Assembly	multimedia:A supplement to the article is available.
5. First Gear, Inner Synchronizer Ring and Cone - Assembly	multimedia:A supplement to the article is available.
6. Second Gear and Half Moon Washers - Assembly	multimedia:A supplement to the article is available.
7. Third Gear, Third Gear Synchronizer Ring - Assembly	multimedia:A supplement to the article is available.
8. New Output Shaft Bearing and Circlip - Assembly	multimedia:A supplement to the article is available.
9. Shift Selector Plate - Assembly	multimedia:A supplement to the article is available.
10. Diff Bearing Race, Magnet, Rev. Idler - Assembly	multimedia:A supplement to the article is available.
11. Input-Output Shaft - Assembly	multimedia:A supplement to the article is available.
12. Selector Shaft Guide Sleeve - Assembly	multimedia:A supplement to the article is available.
13. Belleville Washers and Bearing Race - Assembly	multimedia:A supplement to the article is available.
14. Mating Transmissin Housings - Assembly	multimedia:A supplement to the article is available.
15. New Input-Output Retainer Rings - Assembly	multimedia:A supplement to the article is available.
16. 5th Gear Housing - Assembly	multimedia:A supplement to the article is available.
17. Press 5th Gear onto Input Shaft - Assembly	multimedia:A supplement to the article is available.
18. Output Shaft 5th Gear and Synchronizer - Assembly	multimedia:A supplement to the article is available.
19. 5th Gear Cover - Assembly	multimedia:A supplement to the article is available.
20. Selector Interlock Mechanism - Assembly	multimedia:A supplement to the article is available.
21. Halfshaft Seal Install - Assembly	multimedia:A supplement to the article is available.
22. Gear Shift Cable Bracket - Assembly	multimedia:A supplement to the article is available.
23. Rev. Lamp Switch and Shift Cable Shroud - Assembly	multimedia:A supplement to the article is available.
24. Clutch Slave Cylinder - Assembly	multimedia:A supplement to the article is available.

• 1.
  
  

  • 1.
    
    
    NOTE: Make sure that a new component is installed.

    Install the reverse gear selector lever and the new snap ring.

  • 2.
    
    Install the selector plate and the bolts.

    Torque: 16 lb.ft (22 Nm)

Courtesy of FORD MOTOR COMPANY

• 2.
  
  

  • 1.
    
    
    NOTE: Make sure that new components are installed.

    Position a new bearing with the numbers facing up.

  • 2.
    
    
    NOTE: Make sure that new components are installed.

    Using the special tool install a new bearing. Use Special Service Tool: 308-710 Installer, Bearing Cup.

Courtesy of FORD MOTOR COMPANY

• 3.
  
  Install the differential and the magnet.

Courtesy of FORD MOTOR COMPANY

• 4.
  
  
  • Install the selector shaft.
  • Install the 5th/reverse gear selector rod.
  • Move the selector shaft into the 5th gear position by moving it to the left and down.
  • Install the reverse gear idler.

Courtesy of FORD MOTOR COMPANY

• 5.
  
  Using special tools install the differential bearing cone in the clutch housing. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 307-557 Installer, Ball Bearing.

Courtesy of FORD MOTOR COMPANY

• 6.
  
  Install the differential and the magnet.

Courtesy of FORD MOTOR COMPANY

• 7.
  
  Use a tie strap to fasten the 3-4 shift fork to the output shaft so that the shift fork clears the shift fork interlock when installing the input and output shafts in the clutch housing.

Courtesy of FORD MOTOR COMPANY

• 8.
  
  Install the input shaft, output shaft and selector fork assemblies into the clutch housing.

Courtesy of FORD MOTOR COMPANY

• 9.
  
  Cut and discard the tie strap and install the 1-2 and 3-4 shift forks on the shift fork interlock.

Courtesy of FORD MOTOR COMPANY

• 10.
  
  Install the selector shaft guide sleeve and new upper and lower snap rings.

  • 1.
    
    Push in the selector shaft guide sleeve.

  • 2.
    
    
    NOTE: Make sure that new components are installed.

    Install the new upper and lower snap rings.

Courtesy of FORD MOTOR COMPANY

• 11.
  
  Install the belleville washers, bearing race and secure it by staking the edge of the housing. Use Special Service Tool: 205-075 Installer, Rear Wheel Hub Seal.

Courtesy of FORD MOTOR COMPANY

• 12.
  
  Apply the sealant.

  Material: Motorcraft ® Gasket Maker / TA-16 (WSK-M2G348-A5)

Courtesy of FORD MOTOR COMPANY

• 13.
  
  Install the transmission housing and the bolts and tighten in a crisscross sequence.

  Torque: 16 lb.ft (22 Nm)

Courtesy of FORD MOTOR COMPANY

• 14.
  
  Install the new input shaft and output shaft retaining rings and 5th gear housing gasket.

Courtesy of FORD MOTOR COMPANY

• 15.
  
  Install the 5th gear housing and bolts.

  Torque:

  Stage 1: 106 lb.in (12 Nm)

  Stage 2: 150 lb.in (17 Nm)

• 16.
  
  Remove the following items:
  1. Transmission

Courtesy of FORD MOTOR COMPANY

• 17.
  
  Using the special tool and a press, install the 5th gear wheel onto the input shaft.

  • 1.
    
    
    NOTE: Be sure to support the input shaft on the press when installing 5th gear or the input shaft can be pressed through the rear input shaft bearing and the 5th gear snap ring will not align with the snap ring groove.

    Support the input shaft and install 5th gear using the special tool.

  • 2.
    
    Use Special Service Tool: 205-479 Installer, Drive Pinion Flange. Use the General Equipment: Hydraulic Press

Courtesy of FORD MOTOR COMPANY

• 18.
  
  Install the following items:
  1. Transmission

Courtesy of FORD MOTOR COMPANY

• 19.
  
  
  NOTE: If the 5th gear snap ring does not fit into the groove, check to make sure that the bearing is seated all the way on the input shaft and that the bearing was not moved when 5th gear was pressed on the input shaft.
  NOTE: Make sure that a new component is installed.

  Install a new 5th gear snap ring.

Courtesy of FORD MOTOR COMPANY

• 20.
  
  

  • 1.
    
    Position the selector shaft interlock in the neutral position.

  • 2.
    
    
    NOTE: Make sure that a new component is installed.

    Apply sealant and install the selector interlock mechanism.

    Torque: 18 lb.ft (25 Nm)

Courtesy of FORD MOTOR COMPANY

• 21.
  
  Install the mainshaft 5th gear.

Courtesy of FORD MOTOR COMPANY

• 22.
  
  
  NOTE: This step is only necessary if the original component is to be reused.
  NOTE: Make sure that these components are installed to the position noted before removal.

  Assemble the synchronizer hub and sleeve.

Courtesy of FORD MOTOR COMPANY

• 23.
  
  Install the synchronizer actuators.

Courtesy of FORD MOTOR COMPANY

• 24.
  
  
  NOTE: Make sure that these components are installed to the position noted before removal.

  Install the synchronizer radial spring.

Courtesy of FORD MOTOR COMPANY

• 25.
  
  
  NOTE: Make sure that these components are installed to the position noted before removal.

  Install the synchronizer ring.

Courtesy of FORD MOTOR COMPANY

• 26.
  
  
  NOTE: Make sure that a new component is installed.

  Install the synchronizer and selector fork.

  • Align the marks made during removal.
  • Install the new roll pin. Use the General Equipment: Punch

Courtesy of FORD MOTOR COMPANY

• 27.
  
  
  NOTE: Make sure that a new component is installed.

  Install the new retaining plate and snap ring.

Courtesy of FORD MOTOR COMPANY

• 28.
  
  Apply sealant.

  Material: Motorcraft ® Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)

Courtesy of FORD MOTOR COMPANY

• 29.
  
  Install the 5th gear cover and the 5th gear cover bolts.

  Torque: 106 lb.in (12 Nm)

Courtesy of FORD MOTOR COMPANY

• 30.
  
  

  • 1.
    
    Install the gearshift cables bracket and the nuts.

    Torque: 177 lb.in (20 Nm)

  • 2.
    
    Install selector lever pivot bolt.

    Torque: 34 lb.ft (46 Nm)

Courtesy of FORD MOTOR COMPANY

• 31.
  
  
  NOTE: Make sure that a new component is installed.

  Install new shift shaft seal.

Courtesy of FORD MOTOR COMPANY

• 32.
  
  
  • Install the shift shaft boot.
  • Install the shift lever.
  • NOTE: Make sure that a new bolt is installed.

    Install the shift lever lock bolt.

    Torque: 18 lb.ft (25 Nm)

Courtesy of FORD MOTOR COMPANY

• 33.
  
  
  NOTE: Make sure that a new component is installed.

  Install selector lever and new selector lever snap ring.

Courtesy of FORD MOTOR COMPANY

• 34.
  
  Using the special tool, install the LH halfshaft seal. Use Special Service Tool: 308-880 Installer, Driveshaft Seal.

Courtesy of FORD MOTOR COMPANY

• 35.
  
  Using the special tool, install the RH halfshaft seal. Use Special Service Tool: 205-115A (205-115) Installer, Drive Pinion Seal.

Courtesy of FORD MOTOR COMPANY

• 36.
  
  Install the plug and the retainer.

Courtesy of FORD MOTOR COMPANY

• 37.
  
  Install the gearshift cable shroud and gearshift cable shroud fasteners.

  Torque: 44 lb.in (5 Nm)

Courtesy of FORD MOTOR COMPANY

• 38.
  
  
  NOTE: Inspect the seal to be sure the seal is installed correctly. The seal is installed with the spring toward the transmission. If the seal is not installed correctly, the slave cylinder will interfere with the seal during installation and will result in a leak.
  NOTE: Remove 307-674/1 before using 308-847 to install the seal.

  Install the seal using special tools. Use Special Service Tool: 307-674 Installer, Outer Input Seal., 308-847 Installer, Inputshaft Seal.

Courtesy of FORD MOTOR COMPANY

• 39.
  
  Install the clutch slave cylinder and the clutch slave cylinder bolts.

  Torque: 97 lb.in (11 Nm)

Courtesy of FORD MOTOR COMPANY

• 40.
  
  Remove Special Service Tool: 307-003 (T57L-500-B) Holding Fixture, Transmission.

Courtesy of FORD MOTOR COMPANY