Section 28 (Manual Transmission - 6-Speed Manual Transmission - 3160): Disassembly: 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
| 204-069 (T81P-1104-C) Remover/Installer, Front Wheel Hub | |
|---|---|
| 205-478 Holding Tool, Drive Pinion Flange TKIT-2000AP-FLM/LM TKIT-2002-F/FM | |
| 307-003 (T57L-500-B) Holding Fixture, Transmission | |
| 308-024 (T75L-7025-B) Remover/Installer, Bearing Tube | |
| 308-058 (T77J-7025-H) Remover, Mainshaft Bearing | |
| 308-059 (T77J-7025-J) Remover, Mainshaft Bearing | |
| 308-092 (T84T-7025-B) Removal Screw, Bearing Tube TKIT-1984-F TKIT-1984-FLM TKIT-1984-LM | |
| 308-807 Holding Tool, Rear Flange TKIT-2010A-F TKIT-2010A-LM TKIT-2010A-ROW | |
| 308-958 Remover, 4th Gear | |
| Two Leg Puller | |
| Punch |
WARNING:
Do not breathe dust or use compressed air to blow dust from storage containers or friction components. Remove dust using government-approved techniques. Friction component dust may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure to follow these instructions may result in serious personal injury.
- Clean the transmission exterior with solvent and dry with compressed air. During disassembly, clean all components with solvent and dry with compressed air.
- With the help from an assistant, attach the transmission to the special tool. Use Special Service Tool: 307-003 (T57L-500-B) Holding Fixture, Transmission.
- Using the special tools, hold the output shaft flange and remove and discard the nut. Use Special Service Tool: 308-807 Holding Tool, Rear Flange, 205-478 Holding Tool, Drive Pinion Flange.
- Using the two leg puller and the step plate, remove the output shaft flange. Use the General Equipment: Two Leg Puller
- Remove the shift interlock detent.
- Remove the reverse lamp switch and the reverse switch pin.
- Remove the bolts and slide the extension housing off of the output shaft.
- Remove the shift shaft detent plug and the detent.
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- Remove the slave cylinder bolts.
- Release the tube from the retaining clip.
- Pull the clutch slave cylinder outward and remove it from the input shaft.
- Remove the clutch housing bolts.
- With the help from an assistant, remove the transmission from the clutch housing and set it bottom-side-down on a bench.
- Remove the retainer. Remove the pivot pin and remove the selector lever.
- 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.
- With the help from an assistant, install the transmission in the clutch housing.
- Temporarily install the bolts.
- Using a punch, remove the reverse shift fork roll pin.
- Using a puller, remove reverse gear, the reverse gear hub, reverse gear shift fork, the main shaft rear bearing race and the spacer. Use the General Equipment: Two Leg Puller
- Remove the reverse gear bearing.
- Remove the reverse gear bearing race.
- Using a puller, remove 3rd gear. Use the General Equipment: Two Leg Puller
- Remove the 3rd-4th gear spacer.
- Remove the counter gear rear bearing inner race retainer. Using a puller, remove the counter gear rear bearing inner race.
- Remove the reverse drive gear retainer. Using a puller, remove the reverse drive gear.
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- Remove the 3rd gear thrust washer.
- Remove 3rd gear.
- Remove the 3rd gear bearing.
- Remove the 3rd gear bearing spacer.
- Remove the 3rd gear 3 piece synchronizer assembly.
- Using a punch, remove the roll pin and remove the 3-4 shift fork, sleeve and remove the 3 detents.
- Remove the 3-4 synchronizer hub snap ring.
- Assemble the special tools and remove the 3-4 synchronizer hub. Use Special Service Tool: 308-024 (T75L-7025-B) Remover/Installer, Bearing Tube, 308-058 (T77J-7025-H) Remover, Mainshaft Bearing, 308-059 (T77J-7025-J) Remover, Mainshaft Bearing, 308-092 (T84T-7025-B) Removal Screw, Bearing Tube.
- Remove the 4th gear 3-piece synchronizer assembly.
- Remove 4th gear.
- Remove 4th gear roller bearing.
- Using a punch remove the roll pin and remove the 3-4 shift gate. Use the General Equipment: Punch
- Remove the 5-6 shift gate roll pin access plug.
- Using a punch remove the roll pin and remove the 5-6 shift gate. Use the General Equipment: Punch
- Using a punch remove the roll pin and remove the 1-2 shift gate. Use the General Equipment: Punch
- Remove the rear main shift shaft spacer.
- Using a punch remove the roll pin and remove the selector finger. Use the General Equipment: Punch
- Remove the front main shift shaft spacer.
- Remove the 3 shift shaft detent plugs, springs and detents.
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NOTE: When removing the reverse shift shaft, a shift shaft interlock pin can fall out of the transmission case. Be careful not to lose the shift interlock pin.
Remove the reverse shift shaft. Rotate the reverse shift shaft 90° and remove it from the transmission case.
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NOTE: If the 3-4 shift shaft is dropped after the detent is removed, the 3-4 shift shaft can fall into the transmission case.NOTE: The 3-4 shift shaft can not be removed unless the 5-6 shift shaft is in NEUTRAL.
Remove the 3-4 shift shaft. Be sure that the 5-6 shift shaft is in NEUTRAL. Hold the 3-4 shift shaft up so that it does not fall down into the transmission case. Remove the 3-4 shift shaft detent plug, spring and detent. Remove the 3-4 shift shaft from the transmission case.
- Remove the shift interlock plunger from the 3-4 shift shaft.
- Remove the 2 bolts and the shift interlock support.
- Remove the 3 shift interlock pins.
- Remove the 1-2 shift shaft plunger.
- Using the special tools, remove 4th gear. Use Special Service Tool: 204-069 (T81P-1104-C) Remover/Installer, Front Wheel Hub, 308-958 Remover, 4th Gear.
- Remove the clutch housing bolts.
- Lift up on the transmission case and remove it.
- Remove the 5-6 shift shaft and the main shift shaft.
- 5-6 shift shaft
- Main shift shaft
- Remove the countershaft. Lift the output shaft slightly and position it over and pull the counter shaft up and remove it.
- Remove the output shaft and the shift forks.
- Remove the 3-piece 5th gear synchronizer assembly.
- Remove the input shaft thrust bearing and race.
- Remove the output shaft roller bearing.
- Remove the input shaft.