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Transmission Assembly - Internal Components

WARNING: This page is about a different car, the 2010 Ford F550 Super Duty and 2010 Ford F450 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Exploded View Of Transmission Assembly - Internal
G06778694Courtesy of FORD MOTOR CO.
ITEM DESCRIPTION CHART

Item Description
1 Front bearing retainer bolt (4 required)
2 Front bearing retainer
3 Front bearing retainer
4 Front bearing retainer seal
5 Input shaft shim
6 Input shaft bearing cup
7 Input shaft roller bearing
8 Input shaft
9 Front bearing
10 Clutch cone
11 Synchronizer ring
12 Thrust washer
13 Thrust washer bearing
14 Thrust washer
15 Synchronizer spring
16 Synchronizer hub insert
17 Synchronizer hub, 3rd and 4th
18 Synchronizer collar
19 Synchronizer ring
20 Mainshaft 3rd gear
21 3rd gear bushing
22 Roller bearing
23 Thrust washer
24 Ball bearing
25 Roller bearing
26 Mainshaft 2nd gear
27 Synchronizer ring
28 Snap ring
29 Synchronizer spring
30 Synchronizer hub insert
31 Synchronizer hub, 1st and 2nd gear
32 Synchronizer collar
33 Synchronizer ring
34 Synchronizer intermediate ring
35 Synchronizer inner ring
36 1st gear roller bearing
37 Mainshaft 1st gear
38 Mainshaft
39 Clutch cone
40 Synchronizer ring
41 Snap ring
42 Synchronizer collar
43 Synchronizer spring
44 Synchronizer hub insert
45 Mainshaft reverse gear
46 Roller bearing
47 Ball bearing
48 Thrust washer
49 Roller bearing
50 Roller bearing cup
51 Mainshaft 5th gear
52 Front yoke spacer
53 Ball bearing
54 Rear yoke spacer
55 Output shaft seal
56 Transmission flange
57 Transmission yoke
58 Flange washer
59 Yoke retainer nut
60 Countershaft front bearing cover
61 Countershaft front bearing cup
62 Countershaft front roller bearing
63 Countershaft
64 Countershaft rear roller bearing
65 Countershaft rear bearing cup
66 Countershaft shim
67 Rear bearing retainer
68 Rear bearing retainer bolt (4 required)
69 Ball bearing
70 Thrust washer
71 Roller bearing
72 Roller bearing spacer
73 Roller bearing
74 Synchronizer hub, 5th gear
75 Synchronizer spring
76 Synchronizer hub insert
77 Synchronizer collar
78 Synchronizer ring
79 Clutch cone
80 Snap ring
81 Reverse idler gear
82 Reverse idler bearing
83 Reverse idler bearing spacer
84 Reverse idler bearing
85 Reverse idler shaft
86 Roll pin
NOTE: Apply threadlock to all bolt threads during assembly.
    NOTE: Do not reassemble the transmission dry. Apply lubricant throughout the assembly procedure or damage to the transmission can occur on start-up.
  1. Lubricate all bearings, gears and synchronizers with the recommended transmission lubricant.
  2. Install the countershaft assembly in the transmission case.
  3. Install the 2 reverse idler bearings and spacer into the reverse idler gear.
    Fig 2: Locating Reverse Idler Bearings And Spacer
    G06778607Courtesy of FORD MOTOR CO.
  4. Install the reverse idler gear.
    Fig 3: Locating Reverse Idler Gear
    G06778606Courtesy of FORD MOTOR CO.
  5. Install the reverse idler shaft.
    Fig 4: Locating Reverse Idler Shaft
    G06778605Courtesy of FORD MOTOR CO.
    6. NOTE: Install bearings and cups in matched sets only.
    Fig 5: Locating Countershaft Rear Bearing
    G06778608Courtesy of FORD MOTOR CO.
  6. Install the new countershaft rear bearing and cup.
  7. Install the rear bearing retainer and the 4 bolts.
    • Tighten to 37 Nm (27 lb-ft).
      Fig 6: Locating Rear Bearing Retainer Bolt
      G06778699Courtesy of FORD MOTOR CO.
  8. Using the Dial Indicator Gauge with Holding Fixture, measure the countershaft end play.
    1. Place the transmission in a vertical position and install the Dial Indicator Gauge with Holding Fixture.
    2. Push upward on the countershaft.
    3. Record the Dial Indicator Gauge reading.
      Fig 7: Measuring Countershaft End Play
      G06778700Courtesy of FORD MOTOR CO.
      NOTE: Although zero end play is the ideal, end play up to 0.12 mm (0.004 in) is an acceptable tolerance. Do not overload the bearings with a shim that is too thick as damage may occur.
  9. If necessary, add a shim(s) behind the rear bearing retainer to adjust end play.
    10. NOTE: This step is necessary to gain clearance when installing the mainshaft.
    Fig 8: Locating Rear Bearing Retainer Bolt
    G06778699Courtesy of FORD MOTOR CO.
  10. Remove the 4 rear bearing retainer bolts, retainer and cup.
  11. Using a rope wrapped around the front of the mainshaft, position the rear of the mainshaft though the transmission case and lower the front of the mainshaft down into the transmission main case.
  12. Using a suitable tool and press, install the input shaft bearing.
    Fig 9: Installing Input Shaft Bearing
    G06778702Courtesy of FORD MOTOR CO.
  13. Install the input shaft.
    Fig 10: Locating Input Shaft
    G06778602Courtesy of FORD MOTOR CO.
  14. Install the bearing cup and shim(s) onto the input shaft.
    Fig 11: Locating Input Shaft Shims
    G06778601Courtesy of FORD MOTOR CO.
  15. Apply a 3.2 mm (1/8 in) bead of sealant to the sealing surface of the front bearing retainer. Install the front bearing retainer and the 4 bolts.
    • Tighten to 19 Nm (168 lb-in).
      Fig 12: Locating Front Bearing Retainer Bolt
      G06778600Courtesy of FORD MOTOR CO.
  16. Install the cup, rear bearing retainer and the 4 rear bearing retainer bolts.
    • Tighten to 37 Nm (27 lb-ft).
      Fig 13: Locating Rear Bearing Retainer Bolt
      G06778599Courtesy of FORD MOTOR CO.
  17. Install the ball bearing and the 2 roller bearings with the spacer between the bearings.
    Fig 14: Locating Roller Bearings, Spacer And Ball Bearing
    G06778598Courtesy of FORD MOTOR CO.
  18. Install the 5th gear synchronizer assembly.
    Fig 15: Locating 5th Gear Synchronizer Assembly
    G06778597Courtesy of FORD MOTOR CO.
  19. Install the new snap ring on the 5th gear clutch cone.
    Fig 16: Locating Snap Ring Of 5th Gear Clutch Cone
    G06778596Courtesy of FORD MOTOR CO.
  20. Install the front/rear yoke spacers with the ball bearing between the spacers.
    Fig 17: Locating Front And Rear Yoke Spacers And Ball Bearing
    G06778595Courtesy of FORD MOTOR CO.
  21. Apply a 3.2 mm (1/8 in) bead of sealant to the sealing surface on the rear of the transmission main case and position the extension housing.
  22. Install the 9 extension housing-to-transmission main case bolts and stud.
    • Tighten to 62 Nm (46 lb-ft).
      Fig 18: Locating Extension Housing Bolts
      G06778594Courtesy of FORD MOTOR CO.
  23. Install the transmission mount and the 2 bolts.
    • Tighten to 62 Nm (46 lb-ft).
      Fig 19: Locating Transmission Mount Bolts
      G06778593Courtesy of FORD MOTOR CO.
  24. Install the fuel line support bracket and the bracket nut.
    • Tighten to 62 Nm (46 lb-ft).
      Fig 20: Locating Fuel Tube Support Bracket Nut
      G06778592Courtesy of FORD MOTOR CO.
  25. Using the Drive Pinion Flange Holding Fixture, install the transmission flange washer and retainer nut.
    • Tighten to 160 Nm (118 lb-ft).
      Fig 21: Removing Transmission Flange Retainer Nut And Washer
      G06778558Courtesy of FORD MOTOR CO.
  26. Using the Dial Indicator Gauge with Holding Fixture, measure the mainshaft end play.
    1. Place the transmission in a vertical position and install the Dial Indicator Gauge with Holding Fixture.
    2. Push upward on the mainshaft.
    3. Record the Dial Indicator Gauge reading.
      Fig 22: Measuring Mainshaft End Play
      G06778715Courtesy of FORD MOTOR CO.
      NOTE: Although zero end play is the ideal, end play up to 0.12 mm (0.004 in) is an acceptable tolerance. Do not overload the bearings with a shim that is too thick as damage may occur.
  27. If necessary, add a shim(s) behind the front bearing retainer to adjust end play.
  28. Apply a 3.2 mm (1/8 in) bead of sealant to the sealing surface of the shift control housing. Install the shift control housing and the 10 bolts.
    • Tighten to 27 Nm (20 lb-ft).
      Fig 23: Locating Shift Control Housing Bolt
      G06778589Courtesy of FORD MOTOR CO.
  29. Install the vent hose support bracket bolt.
    • Tighten to 16 Nm (142 lb-in).
      Fig 24: Locating Vent Hose Support Bracket Bolt
      G06778588Courtesy of FORD MOTOR CO.
  30. Remove the transmission from the Transmission Holding Fixture and place on the bench.
    Fig 25: Mounting Transmission To Workbench Using Transmission Holding Fixture
    G06778718Courtesy of FORD MOTOR CO.
  31. Install the clutch housing and the 2 clutch housing-to-transmission case nuts.
    • Tighten to 62 Nm (46 lb-ft).
      Fig 26: Locating Clutch Housing Front Nuts
      G06778586Courtesy of FORD MOTOR CO.
  32. Install the 4 clutch housing-to-transmission case rear bolts.
    • Tighten to 62 Nm (46 lb-ft).
      Fig 27: Locating Clutch Housing Rear Bolts
      G06778585Courtesy of FORD MOTOR CO.
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