Section 28 (Manual Transmission - 6-Speed Manual Transmission - 3160): Assembly: Transmission
WARNING: This page is about a different variant/trim than selected.
For information on Ford Color Coded Illustrations refer to OEM Color Coding .
Special Tool(s) / General Equipment
| 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge | |
|---|---|
| 205-199 (T83T-3132-A1) Installer, Spindle/Axle Shaft T83-4000-A TKIT-1983-F TKIT-1983-FLM TKIT-1983-FX | |
| 205-478 Holding Tool, Drive Pinion Flange TKIT-2000AP-FLM/LM TKIT-2002-F/FM | |
| 308-806 Installer, Front Seal TKIT-2010A-F TKIT-2010A-LM TKIT-2010A-ROW | |
| 308-807 Holding Tool, Rear Flange TKIT-2010A-F TKIT-2010A-LM TKIT-2010A-ROW | |
| 308-957 Installer, Input Shaft Seal | |
| 308-959 Installer, Output Shaft Seal | |
| Punch |
Materials
| Name | Specification |
|---|---|
| Motorcraft® Thread Sealant with PTFE TA-24-B | WSK-M2G350-A2 |
NOTE:
Take note of all components that need to be heated before assembly. Do not heat components above 260 degrees and no longer then 15 minutes.
- Install the input shaft.
- Install the output shaft roller bearing.
- Install the input shaft thrust bearing and race.
- Install the 3-piece 5th gear synchronizer assembly.
- Assemble the 5-6 shift fork and the 1-2 shift fork in the output shaft and install the output shaft into the input shaft.
- Install the countershaft. Position aside the output shaft, align the countershaft with the oil pump drive and install the countershaft.
- Install the 5-6 shift shaft and the main shift shaft.
- 5-6 shift shaft
- Main shift shaft
- Install the clutch housing gasket.
- Install the transmission case.
- Temporarily install the clutch housing bolts.
Torque: 24 lb.ft (33 Nm)
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NOTE: The input shaft/output shaft end play must be measured with a gasket installed between the clutch housing and the transmission main case or incorrect end play will occur.
Measure the input and output shaft end play and select the correct shim.
- Install the special tool on the on the transmission case, place the dial indicator needle on the output shaft and zero the dial indicator. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
- Move the output shaft up and down and record the end play on the dial indicator.
- Select a shim to achieve 0.0127-0.0889 mm end play.
-
NOTE: The countershaft shaft end play must be measured with a gasket installed between the clutch housing and the transmission main case or incorrect end play will occur.
Measure the countershaft end play and select the correct shim.
- Install the special tool on the on the transmission case, place the dial indicator needle on the output shaft and zero the dial indicator. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
- Move the output shaft up and down and record the end play on the dial indicator.
- Select a shim to achieve 0.0127-0.0889 mm end play.
- Heat 4th gear to 260°F. Install 4th gear on the output shaft.
- Install the 1-2 shift shaft plunger.
- Install the 3 shift interlock pins.
- Install the shift interlock support and the 2 bolts.
Torque: 18 lb.ft (25 Nm)
- Install the shift interlock plunger in the 3-4 shift shaft.
-
NOTE: If the 3-4 shift shaft is dropped before the detent is installed, the 3-4 shift shaft can fall into the transmission case.
Install the shift 3-4 shift shaft. Shift the 5-6 shift shaft into the NEUTRAL position. Install the 3-4 shift shaft into the transmission and while holding the 3-4 shift shaft, install the 3-4 shift shaft detent, detent spring and plug.
Material: Motorcraft® Thread Sealant with PTFE / TA-24-B (WSK-M2G350-A2)
Torque: 21 lb.ft (28 Nm)
- Install the reverse shift shaft.
- Install the 3 shift shaft detents, springs and detent plugs.
Material: Motorcraft® Thread Sealant with PTFE / TA-24-B (WSK-M2G350-A2)
Torque: 21 lb.ft (28 Nm)
- Install the front main shift shaft spacer.
- Install the selector finger and install the roll pin. Use the General Equipment: Punch
- Install the rear main shaft spacer.
- Install the 1-2 shift gate and install the roll pin. Use the General Equipment: Punch
- Install the 5-6 shift gate and install the roll pin. Use the General Equipment: Punch
- Install the 5-6 shift gate roll pin access plug.
Material: Motorcraft® Thread Sealant with PTFE / TA-24-B (WSK-M2G350-A2)
- Install the 3-4 shift gate and install the roll pin. Use the General Equipment: Punch
- Install the 4th gear roller bearing.
- Install 4th gear.
- Install the 4th gear 3-piece synchronizer assembly.
-
NOTE: Failure to align the top synchronizer ring with the hub while installing the hub can damage the synchronizer ring.
Install the 3-4 synchronizer hub. Heat the 3-4 synchronizer hub to 260°F. Align one of the top synchronizer ring inner 3 tabs with the output shaft to provide a reference point when installing the 3-4 synchronizer hub. Align the 3-4 synchronizer hub with the top 4th gear synchronizer, with one of the 3 cutouts of the synchronizer hub toward the output shaft and install it on the countershaft. While installing the hub, lift the top 4th gear synchronizer ring and align it with the hub.
- Install 3-4 synchronizer hub snap ring.
- Install the 3-4 synchronizer sleeve, shift fork and the 3 detents. When installing the sleeve, align the indented internal splines with the detent slots in the hub. Using a punch, drive the roll pin into the shift shaft.
- Install the 3rd gear 3 piece synchronizer assembly.
- Install the 3rd gear bearing spacer.
- Install the 3rd gear bearing.
-
- Install 3rd gear.
- Install the 3rd gear thrust washer.
- Heat the reverse drive gear to 260°F. Install the reverse drive gear and install the snap ring.
- Heat the counter gear rear bearing inner race to 260°F. Install the counter gear rear bearing inner race and install the snap ring.
- Install the 3-4 spacer.
- Heat 3rd gear to 260°F. Install 3rd gear on the output shaft.
- Install the reverse gear bearing race.
- Install the reverse gear bearing.
- Install reverse gear.
- Install reverse shift fork and sleeve. When installing the sleeve, align the indented internal splines with the detent slots in the hub.
- Install the 3 reverse detents.
- Install the 3-piece reverse synchronizer.
- Install the reverse synchronizer hub.
- Install the output shaft bearing race spacer.
- Heat the output shaft rear bearing inner race to 260°F. Install the output shaft rear bearing inner race.
- Install the reverse shift fork roll pin. Use the General Equipment: Punch
- Remove the clutch housing bolts.
- Remove the transmission from the clutch housing and set it bottom-side-down on a bench.
- Install the selector lever in the 2 shift rails. Install the pivot pin into the selector lever and install the clip.
Torque: 30 lb.ft (41 Nm)
- Remove the front input shaft and the countershaft bearing races and install the correct thickness shim as determined for the correct end play. Re-install the bearing races.
- Install the clutch housing gasket.
- If equipped with transmission fluid cooling, align the pump pin and the countershaft slots with the center line of the input shaft to aid in installation.
- Install the transmission in the clutch housing.
- Install the clutch housing bolts.
Torque: 24 lb.ft (33 Nm)
- Install the main shift shaft detent.
Torque: 16 lb.ft (22 Nm)
- Install the extension housing gasket.
- Install the extension housing.
Torque: 24 lb.ft (33 Nm)
- Install the reverse switch pin and the reverse lamp switch.
Torque: 16 lb.ft (22 Nm)
- Install the shift interlock detent.
Torque: 30 lb.ft (41 Nm)
- Install the tone wheel.
- Using the special tools, install the output shaft seal. Use Special Service Tool: 205-199 (T83T-3132-A1) Installer, Spindle/Axle Shaft, 308-959 Installer, Output Shaft Seal.
- Install the flange on the output shaft. Install the washer and loosely install a new nut.
- Using the special tools, tighten the output shaft flange nut. Use Special Service Tool: 308-807 Holding Tool, Rear Flange, 205-478 Holding Tool, Drive Pinion Flange.
Torque: 105 lb.ft (143 Nm)
- Install the input shaft seal on the input shaft.
- Using the special tools, install the input shaft seal in the clutch housing. Use Special Service Tool: 308-806 Installer, Front Seal, 308-957 Installer, Input Shaft Seal.
-
- Install the clutch slave cylinder in the clutch housing.
- Install the tube in the retaining clip.
- Install the slave cylinder bolts.
Torque: 97 lb.in (11 Nm)