Section 19 (Manual Transmission - 7-Speed Manual Transmission - Mt88): Assembly: Transmission

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Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	205-153 (T80T-4000-W)Handle
Courtesy of FORD MOTOR COMPANY	205-175Socket, Drive Pinion Nut TKIT-2001-FLM TKIT-2001-ROW TKIT-2002N-LM TKIT-2002-M
Courtesy of FORD MOTOR COMPANY	307-575Converter Seal Installer TKIT-2006UF-FLM TKIT-2006UF-ROW
Courtesy of FORD MOTOR COMPANY	308-806Installer, Front Seal TKIT-2010A-F TKIT-2010A-LM TKIT-2010A-ROW
Courtesy of FORD MOTOR COMPANY	308-809Installer, Syncro Gear Pack TKIT-2010A-ROW
Courtesy of FORD MOTOR COMPANY	308-811Installer, Rear Seal TKIT-2010A-F TKIT-2010A-LM TKIT-2010A-ROW
Courtesy of FORD MOTOR COMPANY	308-883Wrench, Output Shaft Nut
Cable Ties
Hot Air Gun
Punch
Copper Hammer

Materials 

1. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
   NOTE: Clean the sealing surfaces of the front transmission case and the sealing surfaces of the rear transmission case.

   Clean the mating surfaces of the front and rear transmission cases and the mid plate. Refer to: RTV Sealing Surface Cleaning and Preparation

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2. NOTE: Secure the shaft pack with cable ties.

   Assemble the input shaft, counter shaft, shift shafts and forks. Place cable ties around the assembly to hold them together. Use the General Equipment: Cable Ties

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3. NOTE: Do not heat bearings higher than 120 deg.C (248 deg.F) maximum or damage to the bearings can occur.

   Heat up the inner race of the input and counter shaft case bearings. Use the General Equipment: Hot Air Gun

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4. Install the shaft assembly. Remove cable ties.

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5. NOTE: Use care to not scratch the input shaft surfaces or a leak may be the result.
   NOTE: Install the input shaft circlip with the transmission in the vertical position with the input shaft facing down.

   Install the new input shaft circlip.

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6. Install the output shaft to input shaft connection bearing.

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7. Install the output shaft.

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8. Install the gearshift lever pivot bolt.

   Torque: 16 lb.ft (22 Nm)

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9. Position the shift dampener lever inward into the shift shaft driver.

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10. Install the shift dampener lever spacer.

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11. Heat up the output shaft inner bearing race.

    Temperature

    : 247.8 deg.F (120 deg.C)

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12. NOTE: The rear case bolts have to be installed within 15 minutes of applying gasket maker.
    NOTE: Gasket maker should be a 3 mm bead with no breaks in the bead or a leak will be the result.

    Apply a 3 mm consistent bead of gasket maker on the transmission case mounting surface.

    Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

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13. Install the transmission mid plate.

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14. Install the shift gate and the shift gate bolts.

    Torque: 16 lb.ft (22 Nm)

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15. Install the shift selector and the new select gate pin.

    Torque: 89 lb.in (10 Nm)

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16. Install the reverse gear bearing.

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17. Install the reverse gear.

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18. NOTE: Use care to not scratch the output shaft surfaces or leaks and/or premature part failures such as bearings may be the result.
    NOTE: Install a new circlip as necessary.

    Install the crawler/reverse gear synchronizer circlip.

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19. Install the reverse idler gear shaft, bearing and gear.

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20. Install the reverse gear synchronizer rings.

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21. Install the crawler/reverse gear synchronizer and fork.

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22. Install the new crawler/reverse gear synchronizer fork roll pin. Use the General Equipment: Punch

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23. NOTE: Use care to not scratch the output shaft surfaces or leaks and/or premature part failures such as bearings may be the result.
    NOTE: Install a new circlip as necessary.

    Install the crawler/reverse gear synchronizer circlip.

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24. Install the crawler gear synchronizer rings.

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25. Install the crawler gear bearing.

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26. Install the crawler gear.

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27. Install the output shaft thrust washer.

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28. NOTE: The rear case bolts have to be installed within 15 minutes of applying gasket maker.
    NOTE: Gasket maker should be a 3 mm bead with no breaks in the bead or a leak will be the result.

    Apply a 3 mm consistent bead of gasket maker on the transmission mid plate surface.

    Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

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29. 1. Install the special tool on the output shaft and tighten. Use Special Service Tool: 308-809 Installer, Syncro Gear Pack.

       Torque: 155 lb.ft (210 Nm)

    2. NOTE: The rear transmission case needs to be pre heated up to a MAX of 247.8 deg.F (120 deg.C)

       Install the pre heated rear transmission case.

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30. Using a punch and soft face hammer, install the transmission case alignment dowel pins. Use the General Equipment: Punch. Use the General Equipment: Copper Hammer

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31. Install the rear transmission case bolts in the order shown.

    Torque: 20 lb.ft (27 Nm)

    Fig 1: Rear Transmission Case Bolts Tightening Sequence

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32. Remove Special Service Tool: 308-809 Installer, Syncro Gear Pack.

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33. Using the special tool, install the new output shaft oil seal. Use Special Service Tool: 307-575 Converter Seal Installer.

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34. 1. Using a heat gun, heat up the output shaft oil seal thrust pad. Use the General Equipment: Hot Air Gun
    2. Install the output shaft oil seal thrust pad.

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35. Place the transmission in 4th gear.

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36. 1. Assure the transmission is in fourth gear.
    2. Use the special tool to hold the input shaft. Use Special Service Tool: 205-175 Socket, Drive Pinion Nut.
    3. Using the special tool, install the output shaft nut. Use Special Service Tool: 308-883 Wrench, Output Shaft Nut.

       Torque: 133 lb.ft (180 Nm)

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37. NOTE: Install the counter shaft bolt with the transmission in the vertical position with the input shaft facing down.
    1. Rotate the shift dampener counter clockwise and put the transmission in 4th gear.
    2. Using the special tool to hold the input shaft, install the counter shaft bolt. Use Special Service Tool: 205-175 Socket, Drive Pinion Nut.

       Torque: 70 lb.ft (95 Nm)

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38. NOTE: The depth of the counter shaft bolt plug is critical to the oil lubrication of the counter shaft bearings. The counter shaft bolt plug depth needs to be 6.8 mm. If the counter shaft bolt plug depth exceeds 7.3 mm, remove and install a new counter shaft bolt plug.

    Install the counter shaft bolt plug. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 308-811 Installer, Rear Seal.

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39. NOTE: The input shaft seal should be installed approximately to a depth of 3.5 mm.

    Using the special tool, install the input shaft seal. Use Special Service Tool: 308-806 Installer, Front Seal.

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40. NOTE: If the gear position sensor and magnet are being replaced, a new gear position sensor and magnet assembly must be installed as a matched pair with the same serial number.

    Install the gear position sensor and the screws.

    Torque: 89 lb.in (10 Nm)

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41. Install the slave cylinder.

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42. Install the slave cylinder bolts.

    Torque: 89 lb.in (10 Nm)

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43. Install the drain plug.

    Torque: 26 lb.ft (35 Nm)

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