LEMON Manuals: Even more car manuals for everyone
Home >> Mercedes Benz >> 2025 >> eSprinter Base, _NA_ >> Repair and Diagnosis >> External Pages >> Different car >> Section 2368 (Manual Transmission - ZF S6-650 & 65-750 - 6-Speed -- F250-F550 Super Duty (2009)) >> Assembly >> Transmission

Section 2368 (Manual Transmission - ZF S6-650 & 65-750 - 6-Speed -- F250-F550 Super Duty (2009)): Assembly: Transmission

WARNING: This page is about a different car, the 2009 Ford Pickup, 2009 Ford F550 Super Duty, 2009 Ford F450 Super Duty, and 2009 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
Special Tools

Illustration Tool Name Tool Number
GF0001072Courtesy of FORD MOTOR CO.
 Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C)
GF0007207Courtesy of FORD MOTOR CO.
 Fixture, Gear Pack 308-381
GF0000771Courtesy of FORD MOTOR CO.
 Gauge, Clutch Housing 308-021 (T75L-4201-A)
GF0007210Courtesy of FORD MOTOR CO.
 Gear/Bearing Heater 164-R3900
GF0007304Courtesy of FORD MOTOR CO.
 Handle 205-D055 (D81L-4000-A)
GF0000143Courtesy of FORD MOTOR CO.
 Heat Gun 107-R0300 or equivalent
GF0000772Courtesy of FORD MOTOR CO.
 Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A)
GF0001210Courtesy of FORD MOTOR CO.
 Installer, Countershaft Front Bearing Cup 308-390
GF0007305Courtesy of FORD MOTOR CO.
 Installer, Input Shaft Bearing Cup 308-391
GF0007346Courtesy of FORD MOTOR CO.
 Installer, Input Shaft Oil Seal 308-379 (Gas engines only)
GF0007167Courtesy of FORD MOTOR CO.
 Installer, Output Shaft Oil Seal (4WD) 308-383
GF0007168Courtesy of FORD MOTOR CO.
 Installer, Output Shaft Oil Seal (RWD) 308-382
GF0003256Courtesy of FORD MOTOR CO.
 Remover, Bearing Cup 308-047 (T77F-1102-A)
GF0001026Courtesy of FORD MOTOR CO.
 Remover/Installer, Front Wheel Hub 204-069 (T81P-1104-C)
GF0007303Courtesy of FORD MOTOR CO.
 Remover, Input Shaft Bearing Cup 308-S392
GF0007296Courtesy of FORD MOTOR CO.
 Remover/Installer, Thrust Washer Bearing Cup 308-416
GF0000218Courtesy of FORD MOTOR CO.
 Slide Hammer 100-01 (T50T-100-A)
GF0007170Courtesy of FORD MOTOR CO.
 Socket, Mainshaft Lock Nut (36mm) 308-127 (T87T-7025-AH)
Material

Item Specification
Full Synthetic Manual Transmission Fluid
XT-M5-QS		 WSD-M2C200-C
Gasket Maker
TA-16		 WSK-M2G348-A5
Premium Long-Life Grease
XG-1-C or XG-1-K (US); CXG-1-C (Canada)		 ESA-M1C75-B
Threadlock 262
TA-26		 WSK-M2G351-A6
Threadlock and Sealer
TA-25		 WSK-M2G351-A5
Fig 1: Transmission Internal Components - Disassembled View
GF0049378Courtesy of FORD MOTOR CO.
Item Part Number Description
1 7050 Guide tube
2 7029 Input shaft shim (selective fit)
3 7046 Input shaft oil dam bearing ring
4 7025 Input shaft bearing and bearing cup
5 7017 Input shaft
6 7046 Input shaft rear oil dam
7 7120 Input shaft pocket bearing
8 7B331 Snap ring kit
9 7124 Synchronizer assembly, 3rd and 4th gear
10 7196 Mainshaft 3rd gear
11 7N318 Mainshaft 2nd and 3rd gear bushing
12 7K169 Mainshaft needle bearing
13 7056 Mainshaft 2nd gear thrust ring
14 7103 Mainshaft 2nd gear
15 7K169 Mainshaft needle bearing
16 7124 Synchronizer assembly, 1st and 2nd gear
17 7K169 Mainshaft needle bearing
18 7100 Mainshaft 1st gear
19 7061 Mainshaft
20 7N430 Mainshaft middle bearing and bearing cup
21 7K322 Mainshaft needle bearing
22 7Z451 Mainshaft low gear
23 7124 Synchronizer assembly, low and reverse gear
24 7K322 Mainshaft reverse and low gear bearing
25 7D305 Mainshaft reverse gear bushing
26 7142 Mainshaft reverse gear
27 7E254 Output bearing thrust washer
28 7R205 Mainshaft rear bearing
29 7B331 Snap ring kit
30 7089 Transmission flange (RWD vehicles)
31 7045 Transmission flange lock nut (RWD vehicles)
32 7029 Countershaft shim (selective fit)
33 7065 Countershaft front bearing and bearing cup
34 7113 Countershaft
35 7065 Countershaft middle bearing and bearing cup
36 7115 Countershaft rear bearing spacer
37 7124 Synchronizer assembly, countershaft 5th gear
38 7069 Countershaft bushing
39 7K335 Countershaft needle bearing
40 7158 Countershaft 5th gear
41 7A385 Countershaft rear thrust washer
42 7B331 Snap ring kit
43 7065 Countershaft rear bearing
Fig 2: Transmission Internal Components - Disassembled View
GF0049379Courtesy of FORD MOTOR CO.
Item Part Number Description
1 7052 Input oil seal
2 7005 Main case
3 7D362 Shift rail bearing
4 7005 Oil trough
5 7006 Middle case
6 7E213 Check valve
7 7917 Check valve snap ring
8 7A010 Drain plug
9 7B362 Dowel pin
10 7A103 Oil pump body
11 7B150 Oil pump housing
12 7R194 Oil pump snap ring
13 7B362 Dowel pin
14 7052 Output seal
15 7A039 Extension housing (RWD vehicles)
16 7A039 Extension housing (4WD vehicles)
17 7E290 Magnet
18 7D362 Shift rail bearing
19 7141 Reverse idler gear
20 7E139 Reverse idler bearing
21 7140 Reverse idler shaft
22 7723 Reverse idler shaft support
Fig 3: Transmission Shift Components - Disassembled View
GF0049380Courtesy of FORD MOTOR CO.
Item Part Number Description
1 7210 Shift lever (lower)
2 7C371 Shift lever blocks
3 7277 Shift lever boot
4 - Shift housing bolts
5 7203 Shift housing
6 7811 Shift finger
7 7B096 Roll pin (double)
8 7289 Shift fork (1st and 2nd)
9 7240 Shift rail
10 7R359 Main shift rail
11 7289 Shift fork (3rd and 4th)
12 7C113 Shift rail
13 7229 Shift position block
14 7K201 Shift interlock plate
15 7L013 Detent plugs
16 7N120 Detent springs
17 7247 Shift rail detents
18 7243 Main shift rail driver
19 7H419 Shift fork (5th)
20 7682 Shift rail
21 7244 Shift fork (low and reverse)
22 7H418 Shift rail
23 7Z415 Main shift detent
24 7E218 Detent plunger
25 15520 Reverse lamp switch
    CAUTION: Do not reassemble the transmission dry. Apply lubricant throughout the assembly procedure.
  1. Lubricate all bearings, gears and synchronizers with the recommended transmission lubricant during reassembly.
  2. Index-mark the countershaft in relation to the oil pump slot.
    3. Fig 4: Marking Countershaft In Relation To Oil Pump Slot
    GF0007347Courtesy of FORD MOTOR CO.
    Fig 5: Oil Pump Slot In Countershaft
    GF0007348Courtesy of FORD MOTOR CO.
  3. Position the countershaft to the mainshaft on the Gear Pack Assembly Fixture.
    4. Fig 6: Countershaft & Mainshaft
    GF0007349Courtesy of FORD MOTOR CO.
  4. Install the countershaft rear bearing spacer.
    • The countershaft rear bearing spacer can be installed either way.
    5. Fig 7: Countershaft Rear Bearing Spacer
    GF0007350Courtesy of FORD MOTOR CO.
  5. Install the 1st/2nd and 3rd/4th shift fork and shift rail assemblies.
    • The detent groove on the rail faces upward or to the output shaft.
    • All shift forks and rails use double roll pins.
    6. Fig 8: 1st/2nd & 3rd/4th Shift Fork & Shift Rail Assemblies
    GF0007351Courtesy of FORD MOTOR CO.
  6. Install the interlock plate.
    • The stamped part numbers on the interlock plate must face toward the input shaft.
    7. Fig 9: Interlock Plate
    GF0007352Courtesy of FORD MOTOR CO.
  7. Install and position the intermediate housing on the mainshaft, the countershaft and the shift rails.
    • Make sure the detents are clear of the bore area on the intermediate housing.
    8. Fig 10: Intermediate Housing On Mainshaft, Countershaft, & Shift Rails
    GF0007353Courtesy of FORD MOTOR CO.
  8. Install the interlock plate bolts.
    • Tighten to 10 Nm (89 lb-in).
    9. Fig 11: Interlock Plate Bolts
    GF0007354Courtesy of FORD MOTOR CO.
  9. Assemble the 5th gear synchronizer assembly.
    10. Fig 12: Exploded View Of 5th Gear Synchronizer Assembly
    GF0007355Courtesy of FORD MOTOR CO.
  10. Install the 5th gear synchronizer assembly.
    • Install the 5th gear synchronizer with the snap ring on the synchronizer body facing down against the intermediate housing.
    • The 5th gear synchronizer will slide into place and does not require heat to install.
    11. Fig 13: Installing 5th Gear Synchronizer Assembly
    GF0007356Courtesy of FORD MOTOR CO.
    CAUTION: To prevent damage, do not heat the countershaft bushing higher than 150°C (300°F) maximum.
  11. Remove the countershaft bushing from the Gear/Bearing Heater, then install the countershaft bushing.
    12. Fig 14: Installing Countershaft Bushing
    GF0007357Courtesy of FORD MOTOR CO.
    NOTE: Allow the countershaft bushing to cool for 2-4 minutes before installing the countershaft needle bearing.
  12. Install the countershaft needle bearing.
    13. Fig 15: Countershaft Needle Bearing
    GF0007358Courtesy of FORD MOTOR CO.
  13. Install the 5th gear.
    14. Fig 16: 5th Gear
    GF0007359Courtesy of FORD MOTOR CO.
  14. Install the countershaft rear thrust washer and a new snap ring.
    • The snap ring is a selective fit. The correct snap ring should completely fill the groove when seated.
    • Install the snap ring with the small holes upward.
    • Make sure the snap ring is completely seated, with one tab of the snap ring under the gear tooth.
    15. Fig 17: Snap Ring
    GF0007360Courtesy of FORD MOTOR CO.
  15. For vehicles equipped with a diesel engine, install the low gear thrust washer.
    16. Fig 18: Low Gear Thrust Washer (6.0L)
    GF0007361Courtesy of FORD MOTOR CO.
  16. Install the 2 mainshaft low gear needle bearings.
    17. Fig 19: Mainshaft Low Gear Needle Bearings
    GF0007362Courtesy of FORD MOTOR CO.
  17. Install low gear.
    18. Fig 20: Low Gear
    GF0007363Courtesy of FORD MOTOR CO.
  18. Install the low and reverse synchronizer assembly and synchronizer ring.
    • Install the low/reverse gear synchronizer with the shoulder of the sliding sleeve facing down to the low gear.
    • The low/reverse synchronizer body will slide into place and does not require heat to install.
    19. Fig 21: Low & Reverse Synchronizer Assembly
    GF0007364Courtesy of FORD MOTOR CO.
    CAUTION: To prevent damage, do not heat the reverse gear bushing higher than 150°C (300°F) maximum.
  19. Remove the mainshaft reverse gear bushing from the Gear/Bearing Heater, then install the mainshaft bushing.
    20. Fig 22: Mainshaft Reverse Gear Bushing
    GF0007365Courtesy of FORD MOTOR CO.
    NOTE: Allow the mainshaft reverse gear bushing to cool for 2-4 minutes before installing mainshaft needle bearing.
  20. Install the mainshaft needle bearing.
    21. Fig 23: Mainshaft Needle Bearing
    GF0007366Courtesy of FORD MOTOR CO.
  21. Install the reverse gear. Pull the synchronizer sliding sleeve into the neutral position.
    22. Fig 24: Reverse Gear
    GF0007367Courtesy of FORD MOTOR CO.
    CAUTION: To prevent damage, do not heat the output bearing thrust washer higher than 150°C (300°F) maximum.
  22. Remove the output bearing thrust washer from the Gear/Bearing Heater, then using the special tools, install the output bearing thrust washer.
    23. Fig 25: Output Bearing Thrust Washer
    GF0007368Courtesy of FORD MOTOR CO.
    CAUTION: To prevent damage, do not heat the rear mainshaft output bearing higher than 150°C (300°F) maximum.
  23. Remove the mainshaft output bearing from the Gear/Bearing Heater, then using the special tools, install the rear mainshaft output bearing.
    24. Fig 26: Mainshaft Output Bearing
    GF0007369Courtesy of FORD MOTOR CO.
  24. Using the Dial Indicator with Brackets and the Clutch Housing Gauge, check the axial gear clearance at 5th gear.
    • If not within specifications, disassemble and reinspect.
    25. Fig 27: Checking Axial Gear Clearance At 5th Gear Using Dial Indicator With Brackets & Clutch Housing Gauge
    GF0049381Courtesy of FORD MOTOR CO.
  25. Using the Dial Indicator with Brackets and the Clutch Housing Gauge, check the axial gear clearance at low gear.
    • If not within specifications, disassemble and reinspect.
    26. Fig 28: Checking Axial Gear Clearance At Low Gear Using Dial Indicator With Brackets & Clutch Housing Gauge
    GF0049382Courtesy of FORD MOTOR CO.
  26. Using the Dial Indicator with Brackets and the Clutch Housing Gauge, check the axial gear clearance at reverse gear.
    • If not within specifications, disassemble and reinspect.
    27. Fig 29: Checking Axial Gear Clearance At Reverse Gear Using Dial Indicator With Brackets & Clutch Housing Gauge
    GF0049383Courtesy of FORD MOTOR CO.
    NOTE: The snap ring is used on four wheel drive (4WD) vehicles only.
  27. Install a new snap ring.
    • The snap ring is a selective fit. The correct snap ring should completely fill the groove when seated.
    • Install the snap ring with the small holes upward.
    28. Fig 30: Snap Ring
    GF0007232Courtesy of FORD MOTOR CO.
    NOTE: Using an oil stone or emery cloth, lightly condition the shift rails and clean them with transmission fluid before installing the shift forks and shift rails.
    NOTE: Move the interlock plate into the 5th gear position.
  28. Install the 5th gear shift fork and the shift rail.
    29. Fig 31: 5th Gear Shift Fork & Shift Rail
    GF0007373Courtesy of FORD MOTOR CO.
  29. Using a 5 mm (3/16 in) punch, align the roll pin hole with the top hole of the shift fork. Install the double roll pin in the lower hole, then install a roll pin in the upper hole.
    • Do not hit the sealing surface of the intermediate plate.
    • Make sure the slot of the roll pin is facing away from the shift rail.
    30. Fig 32: Roll Pin
    GF0007374Courtesy of FORD MOTOR CO.
    NOTE: Using an oil stone or emery cloth, lightly condition the shift rails and clean them with transmission fluid before installing the shift forks and rails.
    NOTE: Move the interlock plate into the low/reverse position.
  30. Install the low/reverse gear shift fork and the shift rail.
    31. Fig 33: Low/Reverse Gear Shift Fork & Shift Rail
    GF0007375Courtesy of FORD MOTOR CO.
  31. Using a 5 mm (3/16 in) punch, align the roll pin hole with the top hole of the shift fork. Install the double roll pin in the lower hole, then install a roll pin in the upper hole.
    • Make sure the slot of the roll pin is facing away from the shift rail.
    32. Fig 34: Roll Pin
    GF0007376Courtesy of FORD MOTOR CO.
  32. Install the 4 shift detent springs and 4 new detent plugs.
    • Apply Gasket Maker to the detent plugs before installing.
    33. Fig 35: Shift Detent Spring & Detent Plug
    GF0007377Courtesy of FORD MOTOR CO.
  33. Install the main shift rail, aligning the center of the interlock driver with the center of the interlock plate.
    • The part numbers on the main shift rail, shift position block and shift finger face the output side of the transmission. The roll pin groove on the main shift rail with the shorter distance from the end faces the output end.
    34. Fig 36: Main Shift Rail & Interlock Plate
    GF0007378Courtesy of FORD MOTOR CO.
  34. Install the lower shift finger and a new large roll pin, then install a new small roll pin.
    • Make sure the lower shift finger cup is down.
    • Install the large roll pin with the opening away from the gearset.
    • Make sure the center of the interlock driver is aligned with the center of the interlock plate before installing the small pin.
    • Install the small roll pin with the opening 180 degrees from the opening in the large roll pin. The roll pin should extend equally from both sides when correctly installed.
    35. Fig 37: Installing Small Roll Pin With Opening 180 Degrees From Opening In Large Roll Pin
    GF0049384Courtesy of FORD MOTOR CO.
  35. Install the main shift rail driver and a new large roll pin, then install a new small roll pin.
    • Install the large roll pin with the opening away from the gearset.
    • Install the small roll pin with the opening 180 degrees from the opening in the large roll pin.
    36. Fig 38: Main Shift Rail Driver & Roll Pin
    GF0007380Courtesy of FORD MOTOR CO.
    NOTE: Only install the bearing cups in the main case. The following bearing preload adjustment procedure will determine the thickness of the shim to be used.
    NOTE: For vehicles equipped with gasoline engines, the transmission must be elevated, 50-101 mm (2-4 inches), to prevent damage to the input shaft.
  36. Place the main case on the floor. Align the oil pump center shaft with the slot in the countershaft.
    37. NOTE: Do not apply sealer at this time.
    NOTE: Do not damage the input shaft when removing it from the Gear Pack Assembly Fixture.
    NOTE: To aid installation, have an assistant lower the assembly while another guides the assembly into the main case.
  37. Using a suitable lifting device, a suitable chain and 2 S-hooks, lift the intermediate housing and gear assembly into the case.
    • Using the index mark made on the countershaft, make sure the oil pump center shaft is aligned with the slot on the countershaft.
    • Lightly tap the intermediate housing onto the transmission case.
    38. Fig 39: Lifting Intermediate Housing & Gear Assembly
    GF0007220Courtesy of FORD MOTOR CO.
  38. Install the intermediate housing-to-case bolts.
    • Tighten to 23 Nm (17 lb-ft).
    39. Fig 40: Intermediate Housing To Case Bolts
    GF0007219Courtesy of FORD MOTOR CO.
  39. Install the special tools to measure countershaft clearance.
    • Mount the indicator stand to the intermediate housing.
    • Install the Dial Indicator Gauge. Make sure the indicator is off center on the end of the countershaft.
    • Zero the dial indicator.
    40. Fig 41: Checking Countershaft Clearance
    GF0007381Courtesy of FORD MOTOR CO.
    NOTE: The tool is installed on the PTO opening.
  40. Using the special tool, measure for countershaft clearance.
    • Lift up on the 3rd gear counter.
    • Observe the dial indicator reading.
    • Add preload specification 0.02 mm (0.00079 in) and 0.09 mm (0.0035 in) to the dial indicator reading to determine shim thickness range. Countershaft clearance + 0.02 mm (0.00079 in) Preload = Shim size. Countershaft clearance + 0.09 mm (0.0035 in) Preload = Shim size. Choose the shim between the calculated values for the correct preload.
    41. Fig 42: Lifting Up On 3rd Gear Counter
    GF0007382Courtesy of FORD MOTOR CO.
  41. Install the special tools to measure mainshaft clearance.
    • Mount the indicator stand to the intermediate housing.
    • Install the Dial Indicator Gauge. Make sure the indicator is off center on the end of the mainshaft.
    • Zero the dial indicator.
    42. Fig 43: Checking Mainshaft Clearance
    GF0007383Courtesy of FORD MOTOR CO.
  42. Lifting up on the mainshaft, measure the mainshaft clearance.
    • Lift up on low gear.
    • Observe the dial indicator reading.
    • Add preload specification 0.02 mm (0.00079 in) and 0.09 mm (0.0035 in) to the dial indicator reading to determine shim thickness. Measure the thickness of the input shaft oil dam bearing ring at 3 places and subtract the highest dimension. Mainshaft clearance (-) the thickness of the oil dam + 0.02 mm (0.00079 in) Preload = Shim size. Mainshaft clearance (-) the thickness of the oil dam + 0.09 mm (0.0035 in) Preload = Shim size. Choose the shim between the calculated values for the correct preload.
    43. Fig 44: Lifting Up On Low Gear
    GF0007384Courtesy of FORD MOTOR CO.
  43. Remove the special tools, then remove the intermediate housing-to-case bolts.
    44. Fig 45: Intermediate Housing To Case Bolts
    GF0007219Courtesy of FORD MOTOR CO.
  44. Using a suitable lifting device, a suitable chain and 2 S-hooks, lift the intermediate housing and gear assembly out of the case.
    • Place the S-hooks in the area where the bolts were removed.
    45. Fig 46: Lifting Intermediate Housing & Gear Assembly
    GF0007220Courtesy of FORD MOTOR CO.
  45. Using the special tools, remove the input shaft bearing cup.
    46. Fig 47: Removing Input Shaft Bearing Cup
    GF0007311Courtesy of FORD MOTOR CO.
  46. Using the special tools, remove the countershaft bearing cup.
    47. Fig 48: Removing Countershaft Bearing Cup & Shim
    GF0007307Courtesy of FORD MOTOR CO.
    NOTE: Use a Heat Gun on the case bearing cup area to aid installation.
  47. Install the new shim, the new input shaft oil dam bearing ring and the oil trough into the bearing cup bore, then using the special tools, install the input shaft bearing cup.
    • Using the clearance measurement plus the preload, select the appropriate shim and input shaft oil dam bearing ring.
    48. Fig 49: Installing Input Shaft Bearing Cup
    GF0007321Courtesy of FORD MOTOR CO.
    NOTE: Use a Heat Gun on the case bearing cup area to aid installation.
  48. Install the new shim, then using the special tools, install the countershaft bearing cup.
    • Using the clearance measurement plus the preload, select the appropriate shim.
    49. Fig 50: Installing Countershaft Bearing Cup Using Special Tools (205-D055, 308-390)
    GF0049385Courtesy of FORD MOTOR CO.
    CAUTION: Use an oil stone or sanding block to clean the intermediate plate and main case mating surfaces.
    CAUTION: Do not use a silicone sealing compound.
    NOTE: Do not wait longer than 10 minutes to tighten the 2 bolts due to the rapid cure time of the sealant.
  49. Thinly coat the rear sealing surface of the case and the front sealing surface of the intermediate housing with Gasket Maker.
    50. NOTE: For vehicles equipped with gasoline engines, the transmission must be elevated, 50-101 mm (2-4 inches), to prevent damage to the input shaft.
    NOTE: To aid installation, have an assistant lower the assembly while another guides the assembly into the case.
  50. Install the intermediate housing and gear assembly into the case.
    • Using the index mark made on the countershaft, make sure the oil pump center shaft is aligned with the slot on the countershaft.
    • Lightly tap the intermediate housing onto the transmission case.
    51. Fig 51: Lifting Intermediate Housing & Gear Assembly
    GF0007220Courtesy of FORD MOTOR CO.
  51. Install the intermediate housing-to-case bolts.
    • Apply Threadlock and Sealer to the intermediate housing bolts.
    • Tighten to 23 Nm (17 lb-ft).
    52. Fig 52: Intermediate Housing To Case Bolts
    GF0007219Courtesy of FORD MOTOR CO.
    CAUTION: Do not use a silicone sealing compound.
    NOTE: Do not wait longer than 10 minutes to tighten the bolts due to the rapid cure time of the sealant.
  52. Thinly coat the rear sealing surface of the intermediate housing and the extension housing with gasket maker. Install the extension housing and the 19 extension housing bolts.
    • Tighten to 23 Nm (17 lb-ft).
    53. Fig 53: Extension Housing To Intermediate Housing
    GF0007386Courtesy of FORD MOTOR CO.
  53. Apply Threadlock and Sealer to the threads of the main shift detent. Install the detent plunger and the main shift detent.
    • Tighten to 65 Nm (48 lb-ft).
    54. Fig 54: Main Shift Detent
    GF0007387Courtesy of FORD MOTOR CO.
    NOTE: Cross tighten the bolts.
  54. Apply Threadlock and Sealer to the threads of the PTO cover bolts. Install a new gasket and the PTO cover.
    • Tighten to 38 Nm (28 lb-ft).
    55. Fig 55: PTO Cover Bolts
    GF0007388Courtesy of FORD MOTOR CO.
    NOTE: The tool listed is for gasoline equipped vehicles only. To install the seal for diesel equipped vehicles, use a suitable 1.75 inch ID x 10 inch pipe. Make sure the seal is flush with the transmission case.
  55. Using the special tool, install a new input oil seal.
    • Coat the inner diameter of the new input oil seal with Full Synthetic Manual Transmission Fluid.
    56. Fig 56: Installing Input Oil Seal
    GF0007389Courtesy of FORD MOTOR CO.
  56. Apply Threadlock and Sealer to the threads of the guide tube bolts. Install the guide tube.
    • Tighten bolts to 23 Nm (17 lb-ft).
    57. Fig 57: Guide Tube Bolts
    GF0007390Courtesy of FORD MOTOR CO.
  57. Install the release lever and clutch release hub and bearing.
    • Lubricate the ball stud and the clutch release lever. Only apply grease where the clutch release lever comes in contact with the pivot and the release hub and bearing.
    58. Fig 58: Clutch Release Lever And Clutch Release Hub & Bearing
    GF0007212Courtesy of FORD MOTOR CO.
  58. Using the special tool, install a new output oil seal.
    59. Fig 59: Installing Output Oil Seal (RWD)
    GF0007175Courtesy of FORD MOTOR CO.
    Fig 60: Installing Output Oil Seal (4WD)
    GF0007391Courtesy of FORD MOTOR CO.
    NOTE: This step is for 2-wheel drive vehicles only.
  59. Apply Threadlock 262 to the threads of the transmission flange lock nut. Using the holding fixture and the mainshaft lock nut socket, install the transmission flange and a new pinion flange lock nut.
    • Tighten to 330 Nm (244 lb-ft).
    60. Fig 61: Installing Transmission Flange & New Pinion Flange Lock Nut Using Holding Fixture & Mainshaft Lock Nut Socket
    GF0049386Courtesy of FORD MOTOR CO.
  60. Install the shifter.
    • Shift the transmission through all gears to make sure gears shift correctly.
  61. Check transmission preload. Shift the transmission into reverse and rotate the mainshaft.
    • Drag torque should be 2-8 N.m.
  62. Remove the shifter for installation.
scientia non olet · About LEMON Manuals