Selector Shaft - 5.0L Ti-VCT V8 (308kW/418PS): Removal

WARNING: This page is about a different variant/trim than selected.

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.

Remove the transmission. Refer to: Transmission - 5.0L Ti-VCT V8 (308kW/418PS) .
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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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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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 bolts, spacers and the rev matching sensor/SGS (selected gear sensor).

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

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Using the special tools, 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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Using the two leg puller and the 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.
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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.
- 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 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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