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	204-069-01/1 Adapter for 204-069
Courtesy of FORD MOTOR COMPANY	205-153 (T80T-4000-W) Handle
Courtesy of FORD MOTOR COMPANY	307-003 (T57L-500-B) Holding Fixture, Transmission
Courtesy of FORD MOTOR COMPANY	308-130 (T87T-7025-DH) Installer, Shift Rail Needle Bearing TKIT-1987-FLMH
Courtesy of FORD MOTOR COMPANY	308-375 Remover, Input Shaft Seal TKIT-2005U-M TKIT-1999-F/FLM/LT
Courtesy of FORD MOTOR COMPANY	308-810 Remover, Syncro Gear Pack TKIT-2010A-F TKIT-2010A-LM TKIT-2010A-ROW
Courtesy of FORD MOTOR COMPANY	308-812 Remover, Detent 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
Slide Hammer Dent Puller
Slide Hammer
Three Leg Puller
Hydraulic Press
Center Punch
Two Leg Puller

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.
Attach the transmission to the special tool. Use Special Service Tool: 307-003 (T57L-500-B) Holding Fixture, Transmission.

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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.
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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.
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

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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

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Using the special tool, remove and discard the countershaft bolt cover. Use the General Equipment: Slide Hammer Dent Puller

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Install the special tools, position the shift shaft into 4th gear. Use Special Service Tool: 308-938 Remover/Installer, Companion Flange Nut.

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With the help of an assistant, hold the special tools and remove the countershaft bolt.

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Using the special tools, hold the output shaft flange and remove the bolt. Use Special Service Tool: 308-938 Remover/Installer, Companion Flange Nut.

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Using the three leg puller and the step plate, remove the output shaft flange. Use the General Equipment: Three Leg Puller

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Remove and discard the output shaft seal.

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Remove the transmission breather assembly, if necessary.

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Remove the bolts, spacers and the speed sensor.

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Remove the LH and RH reverse gear shift fork pivot bolts.

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Using the special tool and slide hammer, remove the shift rail detents. Use Special Service Tool: 308-812 Remover, Detent. Use the General Equipment: Slide Hammer

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Remove the transmission case bolts.

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NOTE: Use two leg puller OTC-1039 or equivalent.

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

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

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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.
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Remove the 1st/2nd shift fork.
- Inspect the 1st/2nd shift fork for wear or damage. Install new components as necessary.
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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, 204-069-01/1 Adapter for 204-069.
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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.
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Remove the center support bolts.

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

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NOTE: Index-mark the synchronizer sleeve to the synchronizer hub before removal.
1. Mark the Synchronizer and sleeve.
2. Remove the 1st/2nd synchronizer sleeve and detents.
- Inspect the 1st/2nd synchronizer sleeve and detents for wear or damage. Install a new 1st/2nd synchronizer assembly as necessary.
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NOTE: The center support must be pulled up evenly or damaged to the center support or transmission case can occur.

NOTE: Note the position of each synchronizer ring component before removal.
1. Using the push/puller set, step plate and special tool, remove the center support, 2nd gear and the 1st/2nd synchronizer hub. Use Special Service Tool: 308-810 Remover, Syncro Gear Pack, 204-069-01/1 Adapter for 204-069.
- Inspect all the components for wear or damage. Install new components as necessary.
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Remove the bolts and the shift shaft dampener. Replace O-ring if necessary.

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Remove the 2nd gear needle bearing.
- Inspect the 2nd gear needle bearing for wear or damage. Install a new needle bearing as necessary.
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Remove the shift rail mechanism.

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Remove the bolts and the shift gate.

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

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Remove the shift shaft assembly.

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NOTE: The shift shaft washers may fall off as shift shaft is removed.

Remove the shift shaft assembly washers.

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Remove the magnet.

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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.

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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 assemblies. 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

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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.

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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

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