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

WARNING: This page is about a different variant/trim than selected.

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

WARNING: Be prepared to collect escaping fluid.

1.

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.

GFD140572

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3.

Remove the bolts and the slave cylinder.

GFD140573

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4.

Remove the retainer and the plug.

GFD140574

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5.

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

GFD140575

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6.

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

GFD140576

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7.

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

GFD140577

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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.

GFD140578

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9.

Remove and discard the shift shaft seal.

GFD140579

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10.

Remove the 5th gear cover bolts.

GFD140580

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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

GFD140581

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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

GFD140582

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13.

NOTE: Note the position of each component before removal.

Disassemble the synchronizer assembly.

GFD140583

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14.

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

GFD140584

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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.

GFD140585

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16.

Remove the bolts and the 5th gear housing.

GFD140586

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17.

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

GFD140587

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18.

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

GFD140588

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19.

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

GFD140589

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20.

Remove the selector rod and locking plate.

GFD140590

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21.

Remove the input and output shaft with the shift forks.

GFD140591

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22.

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

GFD140592

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23.

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

GFD140593

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24.

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

GFD140594

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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.

GFD140595

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26.

Remove the reverse idle gear.

GFD140596

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27.

Remove the 5th/reverse gear selector rod.

GFD140597

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28.

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

GFD140598

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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.

GFD140599

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