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Transmission - 2.3L EcoBoost (231kW/314PS)

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Special Tool(s) / General Equipment 

GFD288113Courtesy of FORD MOTOR COMPANY
 205-153 (T80T-4000-W) Handle
GFD288141Courtesy of FORD MOTOR COMPANY
 307-003 (T57L-500-B) Holding Fixture, Transmission
GFD288142Courtesy of FORD MOTOR COMPANY
 308-130 (T87T-7025-DH) Installer, Shift Rail Needle Bearing TKIT-1987-FLMH
GFD288107Courtesy of FORD MOTOR COMPANY
 308-375 Remover, Input Shaft Seal TKIT-2005U-M TKIT-1999-F/FLM/LT
GFD288143Courtesy of FORD MOTOR COMPANY
 308-810 Remover, Syncro Gear Pack TKIT-2010A-F TKIT-2010A-LM TKIT-2010A-ROW
GFD288144Courtesy of FORD MOTOR COMPANY
 308-812 Remover, Detent TKIT-2010A-F TKIT-2010A-LM TKIT-2010A-ROW
GFD288117Courtesy of FORD MOTOR COMPANY
 308-938 Remover/Installer, Companion Flange Nut TKIT-2014D-ROW2 TKIT-2014D-FL_ROW
Slide Hammer Dent Puller
Slide Hammer
Three Leg Puller
Hydraulic Press
Center Punch
Two Leg Puller
Locking Pliers
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.
  1. See below to view a video version of this procedure.
    Disassembly Videos

    1. Remove Clutch Slave Cylinder and Input Shaft Seal - Disassembly
    multimedia:A supplement to the article is available.
    2. Remove Countershaft Bolt Cover - Disassembly
    multimedia:A supplement to the article is available.
    3. Remove Countershaft Bolt and Output Shaft Flange Bolt - Disassembly
    multimedia:A supplement to the article is available.
    4. Remove Output Shaft Flange and Output Shaft Seal (2) - Disassembly
    multimedia:A supplement to the article is available.
    5. Remove Output Shaft Speed Sensor and Reverse Lamp Switch - Disassembly
    multimedia:A supplement to the article is available.
    6. Remove Reverse Gear Shift Fork Pivot Bolts - Disassembly
    multimedia:A supplement to the article is available.
    7. Remove Rear Transmission Case - Disassembly
    multimedia:A supplement to the article is available.
    8. Remove Reverse Shift Fork, Shift Rail Assembly and Shift Shaft - Disassembly
    multimedia:A supplement to the article is available.
    9. Remove First Gear and Reverse Gear synchronizer assembly - Disassembly
    multimedia:A supplement to the article is available.
    10. Remove First Gear Needle Bearing and First Gear synchronizer assembly - Disassembly
    multimedia:A supplement to the article is available.
    11. Remove First Gear Pressure Pieces, 1-2 Shift Fork, Shift Rail, Synchronizer Sleeve - Disassembly
    multimedia:A supplement to the article is available.
    12. Remove Interlock Plate, Spring, Center Hub Supports, 1-2- Synchronizer Snap Ring - Disassembly
    multimedia:A supplement to the article is available.
    13. Remove Center Support, 1-2 Synchronizer Hub, Second Gear, Second Gear Synchronizer - Disassembly
    multimedia:A supplement to the article is available.
    14. Remove Second Gear and Center Support Bearings - Disassembly
    multimedia:A supplement to the article is available.
    15. Remove Pivot Bolts, Three-Four and Five-Six Shift Rails and Forks - Disassembly
    multimedia:A supplement to the article is available.
    16. Remove Countershaft, Output Shaft and Input Shaft - Disassembly
    multimedia:A supplement to the article is available.
    17. Remove Fifth Gear, Sixth Gear and Third Gear - Disassembly
    multimedia:A supplement to the article is available.
    18. Remove Third Gear Synchronizer Ring Assembly and Sleeve - Disassembly
    multimedia:A supplement to the article is available.
    19. Remove Fourth Gear and Three-Four Synchronizer Assembly - Disassembly
    multimedia:A supplement to the article is available.
    20. Remove Fifth and Sixth Gear Synchronizer Assembly - Disassembly
    multimedia:A supplement to the article is available.
    21. Remove Input Shaft and Countershaft Bearings - Disassembly
    multimedia:A supplement to the article is available.
    22. Remove Clutch Slave Cylinder Tube Retaining Clip and Transmission Vent Tube - Disassembly
    multimedia:A supplement to the article is available.
    23. Remove Reverse Idler Gear and Output Shaft Bearing - Disassembly
    multimedia:A supplement to the article is available.
  2. Clean the transmission exterior with solvent and dry with compressed air. During disassembly, clean all components with solvent and dry with compressed air.
  3. Attach the transmission to the special tool. Use Special Service Tool: 307-003 (T57L-500-B) Holding Fixture, Transmission.
    GFD288145Courtesy of FORD MOTOR COMPANY
    1. Remove the slave cylinder bolts.
    2. Pull the clutch slave cylinder outward and release the tube from the retaining clip and if equipped, remove the clutch slave cylinder spacer.
    GFD288146Courtesy of FORD MOTOR COMPANY
  5. Inspect the clutch slave cylinder for the following:

    • Damaged boot

    • Leaking brake fluid

    • Worn or damaged release bearing

    • Rotate the release bearing while applying pressure. If the bearing rotation is rough, install a new clutch slave cylinder.

  6. Using the special tools, remove and discard the input shaft seal. Use Special Service Tool: 308-375 Remover, Input Shaft Seal. Use the General Equipment: Slide Hammer
    GFD288147Courtesy of FORD MOTOR COMPANY
  7. Using a center punch, mark a location in the center of the countershaft bolt cover. Using a drill bit of the appropriate size for the dent puller, drill a hole in the center of the countershaft bolt cover. Drill the hole to pierce the countershaft bolt cover approximately 2 mm (0.078 in) in depth. Use the General Equipment: Center Punch
    GFD288148Courtesy of FORD MOTOR COMPANY
  8. Using the special tool, remove and discard the countershaft bolt cover. Use the General Equipment: Slide Hammer Dent Puller
    GFD288149Courtesy of FORD MOTOR COMPANY
  9. Install the special tools, position the shift shaft into 4th gear. Use Special Service Tool: 308-938 Remover/Installer, Companion Flange Nut.
    GFD288150Courtesy of FORD MOTOR COMPANY
  10. With the help of an assistant, hold the special tools and remove the countershaft bolt.
    GFD288151Courtesy of FORD MOTOR COMPANY
  11. Using the special tools, hold the output shaft flange and remove the bolt. Use Special Service Tool: 308-938 Remover/Installer, Companion Flange Nut.
    GFD288152Courtesy of FORD MOTOR COMPANY
  12. Using the three leg puller and the step plate, remove the output shaft flange. Use the General Equipment: Three Leg Puller
    GFD288120Courtesy of FORD MOTOR COMPANY
  13. Remove and discard the output shaft seal.
    GFD288153Courtesy of FORD MOTOR COMPANY
  14. Remove the bolt and the OSS sensor.
    GFD288154Courtesy of FORD MOTOR COMPANY
    1. Detach the electrical connector retainer.
    2. Remove the reverse lamp switch.
    GFD288155Courtesy of FORD MOTOR COMPANY
  16. Remove the LH and RH reverse gear shift fork pivot bolts.
    GFD288156Courtesy of FORD MOTOR COMPANY
  17. Using the special tools, remove the shift rail detents. Use locking pliers with a slide hammer to access the 2 front shift rail detents. Use Special Service Tool: 308-812 Remover, Detent. Use the General Equipment: Locking Pliers. Use the General Equipment: Slide Hammer
    GFD288157Courtesy of FORD MOTOR COMPANY
  18. Remove the transmission case bolts.
    GFD288158Courtesy of FORD MOTOR COMPANY
  19. Using the two leg puller and the 1 1/2 inch step plate, remove the rear transmission case. Use the General Equipment: Two Leg Puller
    GFD288159Courtesy of FORD MOTOR COMPANY
  20. NOTE: To remove the reverse shift fork and the reverse shift rail assembly, the transmission must be in neutral and the groves on the shift rail must be aligned with the interlock plate.

    Remove the reverse shift fork and the reverse shift rail assembly.

    • Inspect the reverse shift fork and reverse shift rail assembly for wear or damage. Install new components as necessary.

    GFD288160Courtesy of FORD MOTOR COMPANY
  21. Using the special tools, remove the shift shaft stop pin. Use Special Service Tool: 308-812 Remover, Detent. Use the General Equipment: Slide Hammer
    GFD288161Courtesy of FORD MOTOR COMPANY
  22. Remove the shift shaft.
    GFD288162Courtesy of FORD MOTOR COMPANY
  23. Using the push/puller set, step plate and special tool, remove the 1st gear, the reverse gear and the reverse gear synchronizer assembly.

    • Inspect the 1st and reverse gears for wear or damage. Install new gears as necessary.

    • Inspect the reverse gear needle bearing and the reverse gear needle bearing race for wear or damage. Install new components as necessary.

    • Inspect the reverse gear synchronizer assembly and the reverse gear synchronizer ring for wear or damage. Install new components as necessary. Use Special Service Tool: 308-810 Remover, Syncro Gear Pack.

    GFD288163Courtesy of FORD MOTOR COMPANY
  24. Remove the 1st gear needle bearing.

    • Inspect the 1st gear needle bearing for wear or damage. Install a new 1st gear needle bearing as necessary.

    GFD288164Courtesy of FORD MOTOR COMPANY
  25. NOTE: Note the position of each synchronizer ring component before removal.

    Remove the 1st gear synchronizer ring assembly.

    • Inspect all synchronizer ring components for wear or damage. Install new components as necessary.

    GFD288165Courtesy of FORD MOTOR COMPANY
  26. NOTE: Slide the synchronizer sleeve up while removing the pressure pieces.

    1. Remove the 3 pressure pieces.

    GFD288166Courtesy of FORD MOTOR COMPANY
  27. NOTE: Index-mark the synchronizer sleeve to the synchronizer hub before removal.

    Remove the 1st/2nd shift fork, the 1st/2nd shift rail and the 1st/2nd synchronizer sleeve.

    • Inspect the 1st/2nd shift fork and the 1st/2nd shift rail for wear or damage. Install new components as necessary.

    • Inspect the 1st/2nd synchronizer sleeve for wear or damage. Install a new 1st/2nd synchronizer assembly as necessary.

    GFD288167Courtesy of FORD MOTOR COMPANY
  28. Remove the magnet.
    GFD288168Courtesy of FORD MOTOR COMPANY
  29. Remove the bolts, spacers, spring and the interlock plate.
    GFD288169Courtesy of FORD MOTOR COMPANY
  30. Remove the center support bolts.
    GFD288170Courtesy of FORD MOTOR COMPANY
  31. Remove the 1st/2nd synchronizer hub snap ring.
    GFD288171Courtesy of FORD MOTOR COMPANY
  32. NOTE: The center support must be pulled up evenly or damaged to the center support or transmission case can occur.

    Using the push/puller set, step plate and special tool, under the center support pull off the center support, 2nd gear and the 1st/2nd synchronizer hub. Use Special Service Tool: 308-810 Remover, Syncro Gear Pack.

    GFD288172Courtesy of FORD MOTOR COMPANY
  33. NOTE: Note the position of each synchronizer ring component before removal.

    Remove the 1st/2nd synchronizer hub, the 2nd gear synchronizer ring assembly and the 2nd gear.

    • Inspect all the components for wear or damage. Install new components as necessary.

    GFD288173Courtesy of FORD MOTOR COMPANY
  34. Remove the 2nd gear needle bearing.

    • Inspect the 2nd gear needle bearing for wear or damage. Install a new needle bearing as necessary.

    GFD288174Courtesy of FORD MOTOR COMPANY
  35. Remove the center support.

    • Inspect the center support for wear or damage. Install a new center support as necessary.

    GFD288175Courtesy of FORD MOTOR COMPANY
  36. NOTE: When removing the bearings, do not over expand the bearing cages or damage to the bearing cages can occur.

    Unlock the bearing cage tabs and slightly expand the bearing cages. Remove the center support bearings by sliding them up the shaft assemblies.

    GFD288176Courtesy of FORD MOTOR COMPANY
  37. Remove the 2 LH and the 2 RH shift fork pivot bolts.
    GFD288177Courtesy of FORD MOTOR COMPANY
  38. Remove the 3rd/4th shift rail and the 3rd/4th shift fork.
    GFD288178Courtesy of FORD MOTOR COMPANY
  39. Remove the 5th/6th shift rail and the 5th/6th shift fork.
    GFD288179Courtesy of FORD MOTOR COMPANY
  40. WARNING: Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury.
    NOTE: Use an assistant when pressing out the countershaft and output shaft, do not allow the shafts to bind during removal.
    NOTE: The countershaft bolt must be removed prior to pressing out the countershaft or damage to the transmission case will occur.

    With an assistant, support the transmission case on flat surface of a hydraulic press. Using the special tools, press the countershaft out of the bearing and remove the countershaft and output shaft. Use Special Service Tool: 205-153 (T80T-4000-W) Handle, 308-130 (T87T-7025-DH) Installer, Shift Rail Needle Bearing. Use the General Equipment: Hydraulic Press

    GFD288180Courtesy of FORD MOTOR COMPANY
  41. NOTE: Removal of the input shaft is only required if damage is found to the input shaft, input shaft seal or input shaft bearing. If damage is not found, no not remove the input shaft.

    Remove the input shaft snap ring.

    GFD288181Courtesy of FORD MOTOR COMPANY
  42. WARNING: Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury.
    NOTE: Use an assistant when pressing out the input shaft, do not allow the input shaft to drop during removal.
    NOTE: Removal of the input shaft is only required if damage is found to the input shaft, input shaft seal or input shaft bearing. If damage is not found, no not remove the input shaft.

    With an assistant, support the transmission case on flat surfaces of a hydraulic press. Using the hydraulic press, remove the input shaft. Use the General Equipment: Hydraulic Press

    GFD288182Courtesy of FORD MOTOR COMPANY
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