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Section 38 (Manual Transmission - 6-Speed Manual Transmission - B6): Installation: Transmission

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Special Tool(s) / General Equipment 

GFD268889Courtesy of FORD MOTOR COMPANY
 205-115A (205-115) Installer, Drive Pinion Seal
Ford Diagnostic Equipment
Transmission Jack
Cable Ties
Retaining Strap
Wooden Block

Materials 

Name Specification
Motorcraft® High Temperature 4x4 Front Axle and Wheel Bearing Grease XG-11 WSS-M1C267-A1
Bostik Never-Seez Regular Grade (nickel free) Anti-Seize and Lubricating Compound -
  1. Apply a thin coating of grease.

    Material

    : Motorcraft® High Temperature 4x4 Front Axle and Wheel Bearing Grease / XG-11 (WSS-M1C267-A1)

    GFD268890Courtesy of FORD MOTOR COMPANY
  2. Install the following items:

    • Use the General Equipment: Transmission Jack
    • Use the General Equipment: Wooden Block
    • Use the General Equipment: Retaining Strap

    GFD268891Courtesy of FORD MOTOR COMPANY
  3. Install the transmission onto the engine.
    GFD268892Courtesy of FORD MOTOR COMPANY
  4. Install the bellhousing bolt.

    Torque

    : 35 lb.ft (48 Nm)

    GFD268893Courtesy of FORD MOTOR COMPANY
  5. Install the bellhousing bolt.

    Torque

    : 35 lb.ft (48 Nm)

    GFD268894Courtesy of FORD MOTOR COMPANY
  6. Install the transmission support insulator bracket.

    Torque

    : 59 lb.ft (80 Nm)

    GFD268895Courtesy of FORD MOTOR COMPANY
  7. Install the transmission support insulator.

    Torque

    : 109 lb.ft (148 Nm)

    GFD268615Courtesy of FORD MOTOR COMPANY
  8. Install the lower bellhousing bolts.

    Torque

    : 35 lb.ft (48 Nm)

    GFD268896Courtesy of FORD MOTOR COMPANY
  9. Install the exhaust support bracket.

    Torque

    : 18 lb.ft (25 Nm)

    GFD268897Courtesy of FORD MOTOR COMPANY
  10. Install the exhaust insulator.

    Torque

    : 19 lb.ft (26 Nm)

    GFD268898Courtesy of FORD MOTOR COMPANY
  11. NOTE: Make sure that the exhaust flexible pipe is not forcibly bent or twisted.

    Apply a thin coating of anti-seize and install the exhaust pipe on the flexpipe.

    Material

    : Bostik Never-Seez Regular Grade (nickel free) Anti-Seize and Lubricating Compound

    Torque

    : 35 lb.ft (48 Nm)

    GFD268899Courtesy of FORD MOTOR COMPANY
  12. Remove the cable ties. Use the General Equipment: Cable Ties
    GFD268900Courtesy of FORD MOTOR COMPANY
  13. Position the starter back and install the bolts.

    Torque

    : 26 lb.ft (35 Nm)

    GFD268901Courtesy of FORD MOTOR COMPANY
  14. NOTE: If the transmission has been replaced or overhauled, the seals do not need to be replaced.

    Remove and discard the RH halfshaft seal.

    GFD268902Courtesy of FORD MOTOR COMPANY
  15. Using the special tool, install a new RH halfshaft seal. Use Special Service Tool: 205-115A (205-115) Installer, Drive Pinion Seal.
    GFD268903Courtesy of FORD MOTOR COMPANY
  16. NOTE: Do not fully install the halfshaft at this time.

    Using part: 97ZT-7M181-A Seal Protector, slide the RH halfshaft into the transmission until the splines are past the seal and remove the seal protector.

    GFD268904Courtesy of FORD MOTOR COMPANY
  17. Insert the RH halfshaft until the intermediate shaft bearing is centered in the concave groove of the intermediate shaft bearing bracket.
    GFD268905Courtesy of FORD MOTOR COMPANY
  18. Install the halfshaft retaining strap.

    Torque

    :Stage 1: Lower nut:: 44 lb.in (5 Nm) Stage 2: Upper nut:: 18 lb.ft (25 Nm) Stage 3: Lower nut:: 18 lb.ft (25 Nm)

    GFD268906Courtesy of FORD MOTOR COMPANY
  19. Install the RH lower control arm in the knuckle.

    Torque

    : 61 lb.ft (83 Nm)

    GFD268907Courtesy of FORD MOTOR COMPANY
  20. Install the RH brake hose on the strut.

    Torque

    : 89 lb.in (10 Nm)

    GFD268908Courtesy of FORD MOTOR COMPANY
  21. Install the LH halfshaft. Refer to: Front Halfshaft LH .
  22. Install both front wheels and tires. Refer to: Wheel and Tire .
  23. Install the roll restrictor and bracket.

    Torque

    :1: 52 lb.ft (70 Nm) 2: 92 lb.ft (125 Nm) 3: 92 lb.ft (125 Nm)

    GFD268909Courtesy of FORD MOTOR COMPANY
  24. Install the 2 top bellhousing bolts and the top starter motor bolt.

    Torque

    : 35 lb.ft (48 Nm)

    GFD268910Courtesy of FORD MOTOR COMPANY
  25. Connect the wiring harness retainer on the back of the transmission.
    GFD268911Courtesy of FORD MOTOR COMPANY
  26. Connect the slave cylinder hydraulic tube to the slave cylinder.
    GFD268912Courtesy of FORD MOTOR COMPANY
  27. Connect the neutral position sensor.
    GFD268913Courtesy of FORD MOTOR COMPANY
  28. Install the shift cable bracket.

    Torque

    : 18 lb.ft (25 Nm)

    GFD268914Courtesy of FORD MOTOR COMPANY
  29. Connect the shift cables, connect the slave cylinder hydraulic tube to the bracket and connect the reverse light switch.
    GFD268915Courtesy of FORD MOTOR COMPANY
  30. Adjust the shift cables. Refer to: Gearshift Cable Adjustment - 6-Speed Manual Transmission - B6 .
  31. Install the battery tray support bracket.

    Torque

    : 35 lb.ft (48 Nm)

    GFD268613Courtesy of FORD MOTOR COMPANY
  32. Install the battery tray. Refer to: Battery Tray .
  33. Install the air cleaner. Refer to: Air Cleaner .
  34. Fill the transmission. Refer to: Transmission Draining and Filling  .
  35. Bleed the clutch hydraulic system. Refer to: Clutch System Bleeding - 6-Speed Manual Transmission - B6 .
  36. Install the underbody shield.
    GFD267444Courtesy of FORD MOTOR COMPANY
  37. After completing the repairs, perform the Misfire Monitor Neutral Profile Correction procedure. Use the General Equipment: Ford Diagnostic Equipment
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