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Section 1576 (Manual Transmission - Tr6060): Disassembly: Transmission: Disassembly

WARNING: This page is about a different car, the 2009 Ford Mustang. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: During disassembly, if any roll pins, retaining rings or bearings are removed, install new components. Install bearings and bearing cups as a set only.
NOTE: For additional information, refer to the exploded view under the ASSEMBLY .
  1. Clean the transmission exterior with solvent and dry with compressed air. During disassembly, clean all components with solvent and dry with compressed air.
  2. Remove the 2 clutch slave cylinder bolts and the clutch slave cylinder.
    3. Fig 1: Locating Clutch Slave Cylinder & Clutch Slave Cylinder Bolts
    GF0001126Courtesy of FORD MOTOR CO.
  3. Remove the clutch hydraulic tube clip and the clutch hydraulic tube connector.
  4. Attach the transmission to the special tool.
    5. Fig 2: Locating Clutch Hydraulic Tube Clip
    GF0001127Courtesy of FORD MOTOR CO.
  5. Rotate the transmission to a horizontal position.
    6. NOTE: Position a drain pan under the transmission.
  6. If the transmission was not drained during removal, remove the drain plug and drain the transmission.
    7. Fig 3: Locating Drain Plug
    GF0001128Courtesy of FORD MOTOR CO.
  7. Remove the output shaft flange nut.
    8. Fig 4: Identifying Output Shaft Flange & Nuts
    GF0001129Courtesy of FORD MOTOR CO.
  8. Using the special tool, remove the output shaft flange.
    9. Fig 5: Removing Output Shaft Flange Using Special Tool
    GF0001130Courtesy of FORD MOTOR CO.
  9. Remove the 4 bolts and the shift detent cover.
    10. Fig 6: Locating Shift Detent Cover & Shift Detent Cover Bolts
    GF0001131Courtesy of FORD MOTOR CO.
  10. Rotate the transmission to a vertical position.
  11. Remove the 8 bolts and carefully separate the extension housing from the transmission.
  12. Using the special tool, remove the bearing race and the spacer.
    13. Fig 7: Locating Bearing Race & Spacer
    GF0001132Courtesy of FORD MOTOR CO.
  13. Remove the output shaft speed (OSS) sensor tone wheel snap ring.
    14. Fig 8: Locating Output Shaft Speed (OSS) Sensor Tone Wheel Snap Ring
    GF0001133Courtesy of FORD MOTOR CO.
  14. Remove the tone wheel and the ball.
    15. Fig 9: Locating Tone Wheel & Ball
    GF0001134Courtesy of FORD MOTOR CO.
  15. Remove the snap ring, the upper spacer, the rear output shaft roller bearing and the lower spacer.
    • Inspect the rear output shaft roller bearing for wear or damage. Install a new bearing as necessary.
    16. Fig 10: Inspecting Rear Output Shaft Roller Bearing For Damage
    GF0001135Courtesy of FORD MOTOR CO.
    NOTE: Position the gearshift lever in 3rd/4th neutral position.
  16. Using a 5/32-inch drift and a hammer, drive the roll pins downward, then remove the reverse shift rail.
    • Discard the roll pins.
    17. Fig 11: Driving Roll Pins Downward, Then Removing Reverse Shift Rail Using A 5/32-Inch Drift & A Hammer
    GF0001136Courtesy of FORD MOTOR CO.
  17. Remove the following:
    1. The reverse gear snap ring.
    2. The reverse gear thrust washer.
    3. The reverse gear.
    4. Discard the reverse gear snap ring.
    5. Inspect reverse gear for wear or damage. Install a new gear as necessary.
    18. Fig 12: Inspecting Reverse Gear For Damage
    GF0001137Courtesy of FORD MOTOR CO.
  18. Remove the reverse gear needle bearing.
    • Inspect the needle bearing for wear or damage. Install a new bearing as necessary.
    19. Fig 13: Locating Reverse Gear Needle Bearing
    GF0001138Courtesy of FORD MOTOR CO.
  19. Remove the 3 piece reverse gear synchronizer blocking ring.
    20. Fig 14: Locating Reverse Gear Synchronizer Blocking Rings
    GF0001139Courtesy of FORD MOTOR CO.
  20. Remove the reverse gear synchronizer snap ring.
    21. Fig 15: Locating Reverse Gear Synchronizer Snap Ring
    GF0001140Courtesy of FORD MOTOR CO.
  21. Remove the reverse shift fork snap ring.
    22. Fig 16: Locating Reverse Shift Fork Snap Ring
    GF0001141Courtesy of FORD MOTOR CO.
  22. Remove the reverse shift fork and the reverse synchronizer.
    • The synchronizer hub is a tight fit on the shaft, and may need to be removed separately. After removing the fork and synchronizer sleeve, carefully pry off the synchronizer hub.
    23. Fig 17: Locating Reverse Shift Fork, Reverse Synchronizer & Strut Retainer
    GF0001142Courtesy of FORD MOTOR CO.
  23. Inspect the synchronizer for the following:
    • Check for worn, nicked or broken teeth. Install a new synchronizer as necessary.
    • Check keys for wear or distortion. Check the springs for distortion. Install a new synchronizer as necessary.
  24. Inspect the synchronizer blocking ring for the following:
    • Check for wear or damage. Install a new synchronizer blocking ring as necessary.
    • Check the clearance between the synchronizer blocking ring and the gear.
      • Position the blocking ring onto the gear. Make sure the correct blocking ring is measured with the correct gear and that the blocking ring is fully seated on the gear.
      • Insert a feeler gauge and measure the clearance, while applying pressure and rotating the blocking ring. The measurement should be the same around the entire circumference. If the clearance is less than 0.75 mm (0.030 in), install new blocking ring.
    25. Fig 18: Inserting Feeler Gauge & Measuring Clearance
    GF0001143Courtesy of FORD MOTOR CO.
  25. Remove the 5th driven gear split ring and retainer.
    26. Fig 19: Locating 5th Driven Gear Split Ring & Retainer
    GF0001144Courtesy of FORD MOTOR CO.
  26. Using the special tools, remove the 5th driven gear.
    27. Fig 20: Removing 5th Driven Gear Using Special Tools
    GF0046455Courtesy of FORD MOTOR CO.
  27. Remove the 5th/6th shift fork snap ring.
    • Discard the snap ring.
    28. Fig 21: Locating 5th/6th Gear Shift Fork & 5th/6th Gear Synchronizer
    GF0001146Courtesy of FORD MOTOR CO.
  28. Remove the reverse drive gear snap ring.
    • Discard the snap ring.
    29. Fig 22: Locating Reverse Drive Gear Snap Ring
    GF0001147Courtesy of FORD MOTOR CO.
  29. Using a suitable puller, remove the reverse drive gear.
    • Inspect reverse drive gear for wear or damage. Install a new gear as necessary.
    30. Fig 23: Removing Reverse Drive Gear Using A Suitable Puller
    GF0001148Courtesy of FORD MOTOR CO.
  30. Remove the following:
    1. The 5th drive gear snap ring.
    2. The 5th drive gear thrust washer.
    3. The 5th drive gear.
    4. Discard the snap ring.
    5. Inspect the 5th drive gear for wear or damage. Install a new gear as necessary.
    31. Fig 24: Inspecting 5th Drive Gear For Damage
    GF0001149Courtesy of FORD MOTOR CO.
  31. Remove the 5th/6th drive gear needle bearing and spacer.
    32. Fig 25: Locating 5th/6th Drive Gear Needle Bearing & Spacer
    GF0001150Courtesy of FORD MOTOR CO.
  32. Remove the 5th/6th gear synchronizer intermediate cone, the 5th/6th gear synchronizer outer cone and the 5th/6th gear synchronizer blocking ring.
    33. Fig 26: Locating 5th/6th Gear Synchronizer Intermediate Cone, Outer Cone & Blocking Ring
    GF0001151Courtesy of FORD MOTOR CO.
  33. Remove the snap ring.
    34. Fig 27: Locating Snap Ring On Countershaft
    GF0001152Courtesy of FORD MOTOR CO.
  34. Remove the 5th/6th gear shift fork and 5th/6th gear synchronizer.
    • The synchronizer hub is a tight fit on the shaft, and may need to be removed separately. Using a suitable puller, remove the synchronizer hub.
    35. Fig 28: Locating 5th/6th Gear Shift Fork & 5th/6th Gear Synchronizer
    GF0001153Courtesy of FORD MOTOR CO.
    Fig 29: Identifying Special Tool 205-D027
    GF0001154Courtesy of FORD MOTOR CO.
  35. Remove the 5th/6th gear synchronizer intermediate cone, the 5th/6th gear synchronizer outer cone and the 5th/6th gear synchronizer blocking ring.
    36. Fig 30: Locating 5th/6th Gear Synchronizer Intermediate Cone, Outer Cone & Blocking Ring
    GF0001155Courtesy of FORD MOTOR CO.
  36. Remove 6th gear.
    37. Fig 31: Locating 6th Gear
    GF0001156Courtesy of FORD MOTOR CO.
  37. Remove the 6th gear needle bearing.
  38. Remove 9 of the clutch housing-to-transmission case bolts.
    39. Fig 32: Locating Clutch Housing-To-Transmission Case Bolts
    GF0001157Courtesy of FORD MOTOR CO.
  39. Remove the vent hose.
    40. NOTE: Rotate the transmission to a vertical position.
  40. Remove the 2 shift lever guide bolts.
    41. Fig 33: Locating Shift Lever Guide Bolts
    GF0001158Courtesy of FORD MOTOR CO.
  41. Remove the 5th/6th and reverse shift lever detent bolt, spring and detent.
    42. Fig 34: Locating 5th/6th & Reverse Shift Lever Detent Bolt, Spring And Detent
    GF0001159Courtesy of FORD MOTOR CO.
  42. Remove the 2 remaining clutch housing-to-transmission case bolts, then remove the transmission case and the front offset lever.
    • Slide the transmission case upward, off the output shaft and shift rails. Hold the offset lever against the guide plate.
  43. Remove the 6th gear spacer and thrust washer.
    44. Fig 35: Locating 6th Gear Spacer & Thrust Washer
    GF0001160Courtesy of FORD MOTOR CO.
  44. Rotate the 5th/6th and reverse shift levers from the shift interlock plate, then remove the 5th/6th and reverse shift rail assembly.
    45. Fig 36: Locating 5th/6th & Reverse Shift Rail Assembly
    GF0001161Courtesy of FORD MOTOR CO.
  45. Lift up the output shaft, then remove the countershaft.
  46. Remove the output shaft and shift rail as an assembly. Separate the shift rail assembly from the output shaft on the work bench.
    47. Fig 37: Locating Output Shaft And Shift Rail
    GF0001162Courtesy of FORD MOTOR CO.
  47. Remove the input shaft, the 4th gear synchronizer blocking ring and the double cone (3 rings).
    48. Fig 38: Locating Input Shaft, 4th Gear Synchronizer Blocking Ring & Double Cone
    GF0001163Courtesy of FORD MOTOR CO.
  48. Remove the countershaft bearing cup and the countershaft shim.
    • Inspect the cup for wear or damage. Install a new cup and bearing as necessary.
    • Inspect the cup bore for wear, scratches or grooves. Install a new transmission adapter plate as necessary.
    49. Fig 39: Locating Input Shaft Bearing Cup
    GF0001164Courtesy of FORD MOTOR CO.
  49. Remove the input shaft bearing cup and input shaft shim.
    • Inspect the cup for wear or damage. Install a new cup and bearing as necessary.
    • Inspect the cup bore for wear, scratches or grooves. Install a new transmission adapter plate as necessary.
    50. Fig 40: Locating Countershaft Bearing Cup
    GF0001165Courtesy of FORD MOTOR CO.
  50. Remove and discard the input shaft seal.
  51. Inspect the clutch housing for cracks. Clean and check the sealing surface for nicks or scratches.
    • If the clutch housing is cracked, install a new housing. If the sealing surface has nicks or scratches, use a soft stone or crocus cloth to remove.
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