Section 37 (Manual Transmission - 5-Speed Manual Transmission - MTX75): Assembly: Transmission

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Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge
Courtesy of FORD MOTOR COMPANY	205-115 Installer, Drive Pinion Seal TKIT-2000-F/FM/FLM
Courtesy of FORD MOTOR COMPANY	303-350 (T89P-6565-A) Compressor, Valve Spring TKIT-1990-LMH TKIT-1989-F TKIT-1989-FM TKIT-1989-FLM
Courtesy of FORD MOTOR COMPANY	307-003 (T57L-500-B) Holding Fixture, Transmission
Courtesy of FORD MOTOR COMPANY	308-001 (T58L-101-B) Remover, Pilot Bearing
Courtesy of FORD MOTOR COMPANY	308-216 (T94P-4451-AH) Dial Indicator Gauge Holding Fixture TKIT-1994-LMH/MH2 TKIT-1994-FH/FMH/FLMH
Courtesy of FORD MOTOR COMPANY	308-224 (T94P-7025-EH) Socket, Input Shaft TKIT-1994-LMH/MH2 TKIT-1994-FH/FMH/FLMH
Courtesy of FORD MOTOR COMPANY	308-S217 (T94P-4451-BH) Shim Selection Set TKIT-1994-LMH/MH2 TKIT-1994-FH/FMH/FLMH
Plastic Mallet
Hot Air Gun

Materials 

1. Attach the transmission to the special tool. Use Special Service Tool: 307-003 (T57L-500-B) Holding Fixture, Transmission.

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2. 1. Apply sealant and install the reverse gear idler shaft.

      Material

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

   2. Fit the temporary bolt.

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3. 1. Remove the temporary bolt.
   2. NOTE: Make sure that new bolts are installed.

      Install the new bolts.

      Torque

      : 18 lb.ft (24 Nm)

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4. 1. Heat the transmission case. Use the General Equipment: Hot Air Gun
   2. Insert bearing races manually.

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5. NOTE: Use a driver to seat the bearing races.

   Install the bearing races. Use the General Equipment: Plastic Mallet

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6. 1. Heat the clutch housing. Use the General Equipment: Hot Air Gun
   2. Install a 1.10 mm measuring shim.
   3. Install 1.00 mm measuring shim.
   4. Insert bearing races manually.

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7. NOTE: Use a driver to seat the bearing races.

   Install the bearing races. Use the General Equipment: Plastic Mallet

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8. Engage 4th gear on the input shaft.

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9. NOTE: Do not lubricate new roller bearings.

   Install the following items:

   1. Install the input shaft.
   2. Install the output shaft.
   3. Install the differential assembly.

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10. NOTE: The guide pins must remain installed in the transmission case.
    NOTE: The mounting faces of the component must be clean and free from foreign bodies and lubricant.

    Install the clutch housing and tighten the bolts in a crisscross sequence.

    Torque

    : 30 lb.ft (40 Nm)

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11. Rotate the input shaft to seat the bearings. Use Special Service Tool: 308-224 (T94P-7025-EH) Socket, Input Shaft.

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12. NOTE: Make sure the dial indicator is off center on the end of the input shaft.

    Install the dial indicator to measure input shaft end play. Make sure the dial indicator is off center on the end of the input shaft. Zero the dial indicator. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.

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13. NOTE: Measure the end play 3 times and average the measurements. (Example: (0.22 mm + 0.23 mm + 0.21 mm) / 3 = 0.22 mm).
    1. Lift the input shaft with a lever.
    2. Observe and record the dial indicator reading.

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14. Install the special tool on the transmission then install the dial indicator to measure output shaft end play. Position the dial indicator to measure 4th gear. Zero the dial indicator. Use Special Service Tool: 308-216 (T94P-4451-AH) Dial Indicator Gauge Holding Fixture., 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.

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15. NOTE: Measure the end play 3 times and average the measurements. (Example: (0.32 mm + 0.33 mm + 0.31 mm) / 3 = 0.32 mm).
    • Lift the output shaft with a lever.
    • Observe and record the dial indicator reading.

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16. 1. Install the special tool and rotate the input shaft while applying pressure on the differential to seat the differential bearings. Use Special Service Tool: 308-224 (T94P-7025-EH) Socket, Input Shaft.

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17. Install the special tool on the transmission then install the dial indicator to measure the differential end play.
18. NOTE: Measure the end play 3 times and average the measurements. (Example: (0.22 mm + 0.23 mm + 0.21 mm) / 3 = 0.22 mm).
    • Install the special tool on the transmission then install the dial indicator to measure the differential end play. Lift the differential with the special tool. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge., 308-S217 (T94P-4451-BH) Shim Selection Set., 303-350 (T89P-6565-A) Compressor, Valve Spring.
    • Observe and record the dial indicator reading.

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19. • Calculate the required adjusting shim thickness for the input shaft:
    • Installed measuring shim thickness: 1.00 mm.
    • Calculated average input shaft end float e. g. 0.22 mm.
    • End float constant: -0.07 mm.
    • Shim thickness required: 1.00 mm +0.22 mm -0.07 mm = 1.15 mm

20. • Calculate the required adjusting shim thickness for the output shaft:
    • Installed measurement shim thickness: 1.00 mm.
    • Calculated average output shaft end float, e.g.: 0.32 mm.
    • Pre-load constant 0.13 mm.
    • Shim thickness required: 1.00 mm +0.32 mm +0.13 mm = 1.45 mm.

21. • Calculate the required adjusting shim thickness for the differential:
    • Installed measurement shim thickness: 1.10 mm.
    • Calculated average differential end float e. g. 0.36 mm.
    • Pre-load constant 0.33 mm.
    • Shim thickness required: 1.10 mm + 0.36 mm +0.33 mm = 1.79 mm.

22. Remove the clutch housing.

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23. Remove the input shaft, output shaft and the differential.

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24. Remove the bearing race. Use Special Service Tool: 308-001 (T58L-101-B) Remover, Pilot Bearing. Use the General Equipment: Hot Air Gun

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25. Remove the bearing races. Use Special Service Tool: 308-001 (T58L-101-B) Remover, Pilot Bearing. Use the General Equipment: Hot Air Gun

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26. 1. Use the General Equipment: Hot Air Gun
    2. Install the measured adjusting shim.
    3. Install the measured adjusting shim.
    4. Install the measured adjusting shim.
    5. Insert bearing races manually.

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27. NOTE: Use a driver to seat the bearing races.

    Install the bearing races. Use the General Equipment: Plastic Mallet

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28. NOTE: Make sure that these components are installed to the noted removal position.

    Assemble the reverse gear idler.

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29. Keep the reverse gear idler shaft bearing block raised while installing the shaft.

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30. Position the synchronizer in N.

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31. Lubricate the input shaft, the output shaft and the differential.

    Material

    : Motorcraft® Dual Clutch Transmission Fluid / XT-11-QDC (WSS-M2C200-D2)

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32. 1. Install the output shaft in the transmission case.
    2. Install the input shaft in the transmission case.
    3. Lift the reverse idler gear retainer and install the input and output shafts in the bearing races.

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33. NOTE: Make sure that these components are installed to the noted removal position.

    Install the following items:

    1. Install the 5th/reverse shift fork.
    2. Install the 3rd/4th shift fork
    3. Install the 1st/2nd shift fork.

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34. Install the following items:
    1. Install the reverse idler gear retainers.

       Material

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

       Torque

       : 25 lb.ft (34 Nm)

    2. Install the shift rails.
    3. Install the magnet.
    4. Install the differential assembly.

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35. Apply the sealant.

    Material

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

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36. NOTE: The guide pins must remain installed in the transmission case.

    Install the clutch housing.

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37. Tighten the bolts in a crisscross sequence.

    Torque

    : 30 lb.ft (40 Nm)

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38. Install the halfshaft seal. Use Special Service Tool: 205-115 Installer, Drive Pinion Seal.

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39. NOTE: Make sure that a new component is installed.

    Apply the sealant.

    Material

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

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40. Install the following items:
    1. Install the halfshaft seal.
    2. NOTE: Cover the input shaft splines with adhesive tape to avoid damaging the input shaft oil seal.
       NOTE: Make sure that a new component is installed.

       Install the clutch slave cylinder.

    3. NOTE: Make sure that new bolts are installed.

       Tighten the bolts.

       Torque

       : 97 lb.in (11 Nm)

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41. Remove the adhesive tape from the input shaft splines.
42. Position the shift forks in neutral.

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43. Apply the sealant.

    Material

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

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44. 1. Set the selector mechanism to the N position.
    2. Install the selector mechanism and tighten the bolts.

       Torque

       : 19 lb.ft (26 Nm)

    3. Tighten the shown bolt.

       Torque

       : 19 lb.ft (26 Nm)

    4. Install the bracket and tighten the nuts.

       Torque

       : 30 lb.ft (40 Nm)

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