Transmission - 5.0L Ti-VCT V8 (308kW/418PS)

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

Courtesy of FORD MOTOR COMPANY	205-153 (T80T-4000-W) Handle
Courtesy of FORD MOTOR COMPANY	308-806 Installer, Front Seal TKIT-2010A-F TKIT-2010A-LM TKIT-2010A-ROW
Courtesy of FORD MOTOR COMPANY	308-808 Installer, Rear Flange TKIT-2010A-F TKIT-2010A-LM TKIT-2010A-ROW
Courtesy of FORD MOTOR COMPANY	308-809 Installer, Syncro Gear Pack TKIT-2010A-ROW
Courtesy of FORD MOTOR COMPANY	308-811 Installer, Rear Seal TKIT-2010A-F TKIT-2010A-LM TKIT-2010A-ROW
Courtesy of FORD MOTOR COMPANY	308-938 Remover/Installer, Companion Flange Nut TKIT-2014D-ROW2 TKIT-2014D-FL_ROW

Materials

Name	Specification
Motorcraft® Threadlock 262 TA-26	WSK-M2G351-A6
Motorcraft® MT82 Transmission Additive XL-18	-
Motorcraft® Gasket Maker TA-16	WSK-M2G348-A5
Motorcraft® Dual Clutch Transmission Fluid XT-11-QDC	WSS-M2C200-D2

Lubricate all components with the recommended transmission fluid before assembling.
Material: Motorcraft® Dual Clutch Transmission Fluid / XT-11-QDC (WSS-M2C200-D2)
NOTE: Do not heat the input shaft bearing higher than 120°C (248°F) maximum or damage to the input shaft bearing can occur.

Using a heat gun, heat the input shaft bearing inner race to a maximum of 120°C (248°F).

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Install the input shaft.

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Install the input shaft snap ring.

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NOTE: Make sure the small diameter side of the output shaft roller bearing cage is facing the input shaft or damage to the output shaft bearing can occur.

With the small diameter side of the output shaft roller bearing cage facing the input shaft, install the output shaft roller bearing.

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NOTE: Apply petroleum jelly to hold the 5th gear synchronizer ring and the 5th gear synchronizer cone in place during assembly.
- Apply petroleum jelly and install the 3rd/4th gear synchronizer detents.
- Apply petroleum jelly and install the 4th gear synchronizer rings.
- Apply petroleum jelly and install the 3rd/4th gear synchronizer cone.
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Assemble the output shaft, countershaft assemblies and the 3rd/4th and 5th/6th shift forks.

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NOTE: Do not heat the countershaft bearing higher than 120°C (248°F) maximum or damage to the countershaft bearing can occur.

Using a heat gun, heat the countershaft bearing inner race to a maximum of 120°C (248°F).

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Install the output shaft and countershaft assembly.

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NOTE: If the output shaft or countershaft are not fully seated, difficulty assembling the transmission, excessive shift effort, noise or damage to the transmission after assembly can occur.

Inspect the output shaft and countershaft to be sure they are fully installed. Compare the depth of the rear 4th gear surface to the deck surface of the transmission case and compare the depth of the countershaft to the countershaft front bearing.
1. The rear surface of 4th gear should be 25.4 mm - 38.1 mm (1 in - 1.5 in) below the transmission case deck surface.
2. The front countershaft surface should be 0.635 mm - 1.905 mm (0.025 in - 0.075 in) deeper then the front countershaft bearing.
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NOTE: If needed, apply petroleum jelly to help the washer stay on the shift shaft.

Install the shift shaft assembly washers.

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Install the shift shaft assembly.

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Install the 3rd/4th and 5th\6th shift rail.

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Install the shift gate and the bolts.
Torque: 18 lb.ft (24 Nm)

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Install the shift rail mechanism.

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NOTE: When installing the bearings, do not over expand the bearing cages or damage to the bearing cages can occur.

Slightly expand the center support bearing cages and slide the center support bearings down the shaft assemblies. Lock the bearing cage tabs.

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Loosely install the center support and finger tighten the bolts.

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NOTE: Install the countershaft bolt with the transmission in the vertical position with the input shaft facing down.

Apply threadlock and install the countershaft bolt.

Material: Motorcraft® Threadlock 262 / TA-26 (WSK-M2G351-A6)

Torque: 70 lb.ft (95 Nm)

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NOTE: The center support must be tightened evenly or damage to the center support or transmission case can occur.

Apply threadlock to the center support bolts and evenly tighten the center support bolts.

Material: Motorcraft® Threadlock 262 / TA-26 (WSK-M2G351-A6)

Torque: 18 lb.ft (24 Nm)

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Install the shift shaft dampener and bolts.
Torque: 18 lb.ft (24 Nm)

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Install the 2nd gear needle bearing.

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Install the 2nd gear.

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NOTE: The synchronizer ring tabs must engage into the gear slots or damage to the synchronizer ring assembly can occur.

Install the 2nd gear synchronizer ring assembly.

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NOTE: The 3 synchronizer ring tabs must engage into the 3 synchronizer hub slots or damage to the synchronizer hub and the synchronizer ring assembly can occur.

NOTE: The long shoulder of the 1st/2nd synchronizer hub must be facing 2nd gear or damage to the synchronizer hub can occur.

With the long shoulder of the 1st/2nd synchronizer hub must be facing 2nd gear, use the special tool and install the 1st/2nd synchronizer hub. Use Special Service Tool: 308-809 Installer, Syncro Gear Pack.

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NOTE: Slide the synchronizer sleeve up to install the pressure pieces.

With the groove on the 1st/2nd synchronizer sleeve facing 2nd gear, install the synchronizer sleeve and the 3 synchronizer detents.

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NOTE: The synchronizer ring tabs must engage into the gear slots or damage to the synchronizer ring assembly can occur.

Install the 1st gear synchronizer ring assembly.

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Install the 1st/2nd synchronizer hub snap ring.

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Install the 1st gear needle bearing.

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NOTE: The synchronizer ring tabs must engage into the gear slots or damage to the synchronizer assembly and synchronizer ring assembly can occur.

Install the 1st gear.

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Using the special tool, install the reverse gear needle bearing race. Use Special Service Tool: 308-809 Installer, Syncro Gear Pack.

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Install the reverse gear needle bearing.

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Install the reverse gear.

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Install the reverse gear synchronizer rings.

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NOTE: The 3 synchronizer ring tabs must engage into the 3 synchronizer assembly slots or damage to the synchronizer assembly and the synchronizer ring can occur.

Using the special tool, install the reverse gear synchronizer assembly. Use Special Service Tool: 308-809 Installer, Syncro Gear Pack.

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Install the 1st/2nd shift fork.

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

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Install the 1st\2nd and reverse shift rail.

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Install the internal case magnet.

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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.

Make sure that the mating faces are clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation .

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NOTE: Art shown with internal components removed for clarity.

NOTE: Do not wait longer than 10 minutes to install the rear transmission case assembly due to rapid cure of the sealant.

Clean the sealing surfaces of the front transmission case and the sealing surfaces of the rear transmission case. Thinly coat the sealing surface of the front transmission case assembly and the sealing surface of the rear transmission case assembly with gasket maker.

Material: Motorcraft® Gasket Maker / TA-16 (WSK-M2G348-A5)

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NOTE: The rear transmission case assembly must be installed evenly with the transmission shifted into 4th gear, do not allow the shift rails to bind during installation or damage to the transmission case assembly can occur.

Using the special tools, install the rear transmission case assembly. Use Special Service Tool: 308-809 Installer, Syncro Gear Pack, 308-808 Installer, Rear Flange.

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Loosely install the bolts.

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Using a brass drift, tap the dowel pins flush with the transmission case.

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Tighten the transmission case bolts.
Torque: 18 lb.ft (24 Nm)

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Using a soft-faced hammer install the 4 shift rail detents.

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NOTE: Make sure the shift fork pivot bolts engage into the shift fork or damage to the shift fork can occur.

Apply threadlock and sealer and install the LH and RH reverse gear shift fork pivot bolts.

Material: Motorcraft® Threadlock 262 / TA-26 (WSK-M2G351-A6)

Torque: 27 lb.ft (37 Nm)

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Install the speed sensor, spacers and the bolts.
Torque: 89 lb.in (10 Nm)

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Install the transmission breather assembly.

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Install a new output shaft seal on the special tools. Use Special Service Tool: 308-811 Installer, Rear Seal, 205-153 (T80T-4000-W) Handle.

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Using the special tools, install the output shaft seal. Use Special Service Tool: 308-811 Installer, Rear Seal, 205-153 (T80T-4000-W) Handle.

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Using the special tools, install the output shaft flange. Use Special Service Tool: 308-809 Installer, Syncro Gear Pack, 308-808 Installer, Rear Flange.

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Clean the threads on the output shaft bolt and apply one dot of threadlock to the lower end of the output shaft bolt threads. Using the special tools, install the output shaft flange bolt and tighten in 3 stages. Use Special Service Tool: 308-938 Remover/Installer, Companion Flange Nut.
Material: Motorcraft® Threadlock 262 / TA-26 (WSK-M2G351-A6)

Torque: Stage 1: 148 lb.ft (200 Nm) Stage 2: Loosen: 5 turn(s) Stage 3: 133 lb.ft (180 Nm)

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Install the countershaft bolt cover in the clutch housing. Using the special tools, drive the countershaft bolt cover into the clutch housing. Use Special Service Tool: 308-811 Installer, Rear Seal, 205-153 (T80T-4000-W) Handle.

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

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1. Position the clutch slave cylinder and if equipped, the clutch slave cylinder spacer and connect the tube in the retaining clip.
2. Install the 2 bolts.
  Torque: 97 lb.in (11 Nm)
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Add 1 bottle (.91 fl oz (27 ml)) of XL-18 to the transmission if a new synchronizer was installed.
Material: Motorcraft® MT82 Transmission Additive / XL-18