Section 4 (Manual Transmission - 5-Speed Manual Transmission - B5/IB5): Assembly: Transmission
WARNING: This page is about a different variant/trim than selected.
Special Tool(s) / General Equipment
| 205-075Installer, Rear Wheel Hub Seal | |
|---|---|
| 205-115A (205-115)Installer, Drive Pinion Seal | |
| 205-153 (T80T-4000-W)Handle | |
| 205-479Installer, Drive Pinion FlangeTKIT-2000AP-FLM/LMTKIT-2002-F/FM | |
| 307-003 (T57L-500-B)Holding Fixture, Transmission | |
| 307-557Installer, Ball BearingTKIT-2005U-FLMTKIT-2005U-LMTKIT-2006U-FLM/LMTKIT-2006UF/FM | |
| 307-674Installer, Outer Input SealTKIT-2010D-FLMTKIT-2010D-ROW | |
| 308-847Installer, Inputshaft Seal | |
| 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.
- 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)
- 1.
- 2.
- 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.
- 3.
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.
- 5.
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.
- 7.
Cut and discard the tie strap and install the 1-2 and 3-4 shift forks on the shift fork interlock.
- 8.
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.
- 1.
- 9.
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.
- 11.
Install the transmission housing and the bolts and tighten in a crisscross sequence.Torque: 16 lb.ft (22 Nm)
- 13.
Install the 5th gear housing and bolts.Torque:
Stage 1: 106 lb.in (12 Nm)
Stage 2: 150 lb.in (17 Nm)
- 15.
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
- 1.
- 17.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.
- 18.
- 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)
- 1.
- 20.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.
- 22.NOTE: Make sure that these components are installed to the position noted before removal.
Install the synchronizer radial spring.
- 23.NOTE: Make sure that these components are installed to the position noted before removal.
Install the synchronizer ring.
- 24.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
- 25.NOTE: Make sure that a new component is installed.
Install the new retaining plate and snap ring.
- 28.
- 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)
- 1.
- 30.
- 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)
- 31.NOTE: Make sure that a new component is installed.
Install selector lever and new selector lever snap ring.
- 32.
Using the special tool, install the LH halfshaft seal. Use Special Service Tool: 308-880 Installer, Driveshaft Seal.
- 33.
Using the special tool, install the RH halfshaft seal. Use Special Service Tool: 205-115A (205-115) Installer, Drive Pinion Seal.
- 36.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.