Section 4 (Manual Transmission - 5-Speed Manual Transmission - B5/IB5): Disassembly: Transmission

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	100-001 (T50T-100-A)Slide Hammer
Courtesy of FORD MOTOR COMPANY	205-062Installer, Differential Bearing
Courtesy of FORD MOTOR COMPANY	205-D012 (D80L-630-1)Step Plate
Courtesy of FORD MOTOR COMPANY	307-003 (T57L-500-B)Holding Fixture, Transmission
Courtesy of FORD MOTOR COMPANY	307-318Remover, Stator BearingTKIT-1994-FHTKIT-1994-FMH/FLMHTKIT-1994-LMH/MH
Courtesy of FORD MOTOR COMPANY	308-082Remover, Input Shaft Fifth GearTKIT-2000-F/FM/FLM
Scraper for Straight Edges
Punch

• 1.
  
  See below to view a video of this procedure.

1. Clutch Slave Cylinder - Disassembly	multimedia:A supplement to the article is available.
2. Gearshift Cable Shroud - Disassembly	multimedia:A supplement to the article is available.
3. Selector Shaft Interlock Mechanism and 5th Gear Cover - Disassembly	multimedia:A supplement to the article is available.
4. 5th Gear Synchronizer and Selector Fork - Disassembly	multimedia:A supplement to the article is available.
5. Input Shaft 5th Gear - Disassembly	multimedia:A supplement to the article is available.
6. 5th Gear Housing - Disassembly	multimedia:A supplement to the article is available.
7. Transmission Housing From Clutch Housing - Disassembly	multimedia:A supplement to the article is available.
8. Upper-Lower Snap Rings from Selector Rod Guide Sleeve - Disassembly	multimedia:A supplement to the article is available.
9. Input and Output Shafts - Disassembly	multimedia:A supplement to the article is available.
10. Differential Magnet and Reverse Idler - Disassembly	multimedia:A supplement to the article is available.
11. Differential Bearing Race Clutch Side - Disassembly	multimedia:A supplement to the article is available.
12. Reverse Idler Gear Selector lever - Selector Shift Gate - Disassembly	multimedia:A supplement to the article is available.
13. Input Shaft and Output Shaft Oil Seals - Disassembly	multimedia:A supplement to the article is available.
14. Differential Oil Seal-Bearing Race - Transmission Case - Disassembly	multimedia:A supplement to the article is available.
15. Remove the Differential Ring Gear Bolts - Disassembly	multimedia:A supplement to the article is available.
16. Remove the Differential Bearing - Disassembly	multimedia:A supplement to the article is available.
17. Remove the Pinion Shaft and Gears - Disassembly	multimedia:A supplement to the article is available.
18. Remove the Input Shaft Bearings - Disassembly	multimedia:A supplement to the article is available.
19. Output Shaft Bearing - Disassembly	multimedia:A supplement to the article is available.
20. Output Shaft 4th Gear and 3rd Gear - Disassembly	multimedia:A supplement to the article is available.
21. Output Shaft Half Moon Washers - Disassembly	multimedia:A supplement to the article is available.
22. Output Shaft 1st Gear - Disassembly	multimedia:A supplement to the article is available.

• 2.
  
  Install the special tool on the clutch housing and install the transmission on a bench. Install Special Service Tool: 307-003 (T57L-500-B) Holding Fixture, Transmission.

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• 3.
  
  Remove the bolts and the slave cylinder.

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• 4.
  
  Remove the retainer and the plug.

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• 5.
  
  Remove the gearshift cable shroud retainers and the gearshift cable shroud.

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• 6.
  
  Remove the selector lever.
  • Remove and discard the snap-ring.
  • Remove the selector lever.

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• 7.
  
  Remove the gearshift cable bracket nuts and remove the gearshift cable bracket.

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• 8.
  
  
  • Remove and discard the shift lever lock bolt, remove the shift lever.
  • Remove and discard the selector shaft interlock mechanism.

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• 9.
  
  Remove and discard the shift shaft seal.

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• 10.
  
  Remove the 5th gear cover bolts.

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• 11.
  
  
  NOTE: Take extra care not to damage the mating faces.

  Using the scraper remove the 5th gear cover. Use the General Equipment: Scraper for Straight Edges

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• 12.
  
  
  NOTE: Note the position of each component before removal.

  Remove the 5th gear synchronizer unit and selector fork.

  • Remove and discard the snap ring.
  • Remove and discard the roll pin. Use the General Equipment: Punch

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• 13.
  
  
  NOTE: Note the position of each component before removal.

  Disassemble the synchronizer assembly.

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• 14.
  
  Remove and discard the 5th gear snap ring and remove the mainshaft 5th gear.

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• 15.
  
  Using the special tool, remove the input shaft 5th gear. Use Special Service Tool: 308-082 Remover, Input Shaft Fifth Gear., 205-D012 (D80L-630-1) Step Plate.

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• 16.
  
  Remove the bolts and the 5th gear housing.

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• 17.
  
  Remove the input shaft and output shaft retaining rings and remove the 5th gear housing gasket.

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• 18.
  
  Remove the bolts and separate the transaxle housing from the clutch housing.

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• 19.
  
  Remove and discard the 2 snap rings and remove the selector rod guide sleeve.

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• 20.
  
  Remove the selector rod and locking plate.

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• 21.
  
  Remove the input and output shaft with the shift forks.

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• 22.
  
  Remove the differential and the magnet. Remove and discard the input shaft oil seal. Use the General Equipment: Punch

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• 23.
  
  Remove and discard the halfshaft oil seal. Use the General Equipment: Punch

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• 24.
  
  Remove the transmission case side differential bearing race. Use Special Service Tool: 205-062 Installer, Differential Bearing.

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• 25.
  
  Remove the clutch housing side differential bearing race. Use Special Service Tool: 100-001 (T50T-100-A) Slide Hammer., 307-318 Remover, Stator Bearing.

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• 26.
  
  Remove the reverse idle gear.

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• 27.
  
  Remove the 5th/reverse gear selector rod.

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• 28.
  
  Remove the snap ring and the reverse gear selector lever. Remove the bolts and the selector plate.

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• 29.
  
  Inspect the output shaft bearing and bearing race for damage or excessive wear. Install a new transmission if the bearing or the race is damaged or worn.

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