Special Tool(s)

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.

SPECIAL TOOL DESCRIPTION CHART

Courtesy of FORD MOTOR CO.	2 or 3 Jaw Puller 205-D027 (D80L-1013-A) or equivalent
Courtesy of FORD MOTOR CO.	Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A)
Courtesy of FORD MOTOR CO.	Holding Fixture, Transmission 307-003 (T57L-500-B)
Courtesy of FORD MOTOR CO.	Puller, Bearing 205-D064 (D84L-1123-A) or equivalent

WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury.

NOTE: For additional information, refer to the TRANSMISSION ASSEMBLY VIEWS . Refer to TRANSMISSION .

Clean the transmission exterior with solvent and dry with compressed air.
Remove the 4 clutch housing rear bolts.

Fig 1: Locating Clutch Housing Rear Bolts
Courtesy of FORD MOTOR CO.
Remove the 2 clutch housing front nuts and the clutch housing.

Fig 2: Locating Clutch Housing Front Nuts
Courtesy of FORD MOTOR CO.
Using the Transmission Holding Fixture, mount the transmission to the workbench.

Fig 3: Mounting Transmission To Workbench Using Transmission Holding Fixture
Courtesy of FORD MOTOR CO.
Remove the vent hose support bracket bolt.

Fig 4: Locating Vent Hose Support Bracket Bolt
Courtesy of FORD MOTOR CO.
Remove the 10 shift control housing bolts and the housing.

Fig 5: Locating Shift Control Housing Bolt
Courtesy of FORD MOTOR CO.
Using the Drive Pinion Flange Holding Fixture, remove the transmission flange retainer nut and washer.

Fig 6: Removing Transmission Flange Retainer Nut And Washer
Courtesy of FORD MOTOR CO.
Using the 2 or 3 Jaw Puller, remove the transmission flange.

Fig 7: Removing Transmission Flange
Courtesy of FORD MOTOR CO.
Remove the fuel tube support bracket nut and the bracket.

Fig 8: Locating Fuel Tube Support Bracket Nut
Courtesy of FORD MOTOR CO.
Remove the 2 transmission mount bolts and the mount.

Fig 9: Locating Transmission Mount Bolts
Courtesy of FORD MOTOR CO.
Remove the 9 extension housing bolts, stud and housing.

Fig 10: Locating Extension Housing Bolts
Courtesy of FORD MOTOR CO.

NOTE: A ball bearing is located between both spacers.
Remove the front and rear yoke spacers and the ball bearing.

Fig 11: Locating Front And Rear Yoke Spacers And Ball Bearing
Courtesy of FORD MOTOR CO.
Remove the snap ring from the 5th gear clutch cone.
- Discard the snap ring.
  
  Fig 12: Locating Snap Ring Of 5th Gear Clutch Cone
  Courtesy of FORD MOTOR CO.
Remove the 5th gear synchronizer assembly.

Fig 13: Locating 5th Gear Synchronizer Assembly
Courtesy of FORD MOTOR CO.

NOTE: A ball bearing is located behind the last roller bearing.
Remove the 2 roller bearings, spacer and ball bearing from the countershaft.

Fig 14: Locating Roller Bearings, Spacer And Ball Bearing
Courtesy of FORD MOTOR CO.
Remove the 4 rear bearing retainer bolts, retainer and bearing cup.

Fig 15: Locating Rear Bearing Retainer Bolt
Courtesy of FORD MOTOR CO.
Remove the 4 front bearing retainer bolts and the retainer.

Fig 16: Locating Front Bearing Retainer Bolt
Courtesy of FORD MOTOR CO.
Remove the shim(s) and bearing cup from the input shaft.

Fig 17: Locating Input Shaft Shims
Courtesy of FORD MOTOR CO.
Remove the input shaft.

Fig 18: Locating Input Shaft
Courtesy of FORD MOTOR CO.

NOTE: Hold the input shaft so it does not fall.
Using the Bearing Puller and a suitable press, press the input shaft bearing off the input shaft.
- Discard the bearing.
  
  Fig 19: Pressing Input Shaft Bearing Off Input Shaft
  Courtesy of FORD MOTOR CO.
Using a rope wrapped around the front of the mainshaft, lift the front of the mainshaft up and remove from the transmission case.

Fig 20: Removing Transmission Case
Courtesy of FORD MOTOR CO.
Remove the reverse idler shaft.

Fig 21: Locating Reverse Idler Shaft
Courtesy of FORD MOTOR CO.
Remove the reverse idler gear.

Fig 22: Locating Reverse Idler Gear
Courtesy of FORD MOTOR CO.
Remove the 2 reverse idler bearings and the spacer from the reverse idler gear.

Fig 23: Locating Reverse Idler Bearings And Spacer
Courtesy of FORD MOTOR CO.
Remove the countershaft rear bearing and cup.

Fig 24: Locating Countershaft Rear Bearing
Courtesy of FORD MOTOR CO.
Remove the countershaft assembly from the transmission main case.