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

Illustration	Tool Name	Tool Number
Courtesy of FORD MOTOR CO.	2- or 3-Jaw Puller	205-D027 (D80L-1013-A)
Courtesy of FORD MOTOR CO.	Center Plate Legs	308-380
Courtesy of FORD MOTOR CO.	Fixture, Gear Pack	308-381
Courtesy of FORD MOTOR CO.	Gear/Bearing Heater	164R-3900
Courtesy of FORD MOTOR CO.	Holding Fixture, Drive Pinion Flange	205-126 (T78P-4851-A)
Courtesy of FORD MOTOR CO.	Remover/Installer, Front Wheel Hub	204-069 (T81P-1104-C)
Courtesy of FORD MOTOR CO.	Remover, Jet Plug	310-005 (T77L-9533-B)
Courtesy of FORD MOTOR CO.	Shaft Protector Set	205-DS004 (D80L-625-A)
Courtesy of FORD MOTOR CO.	Socket, Mainshaft Lock Nut (36 mm)	308-127 (T87P-7025-AH)

All vehicles 

1. Clean the transmission exterior with solvent and dry with compressed air.
2. Remove the clutch release lever and the clutch release hub and bearing.
Fig 1: Clutch Release Lever And Clutch Release Hub & Bearing
Courtesy of FORD MOTOR CO.
NOTE: For vehicles equipped with gasoline engines, the transmission must be elevated 50-101 mm (2-4 in) to prevent damage to the input shaft.
3. Position the transmission on the floor with the output flange pointing upward.
Fig 2: Positioning Transmission On Floor With Output Flange Pointing Upward
Courtesy of FORD MOTOR CO.

Rear wheel drive (RWD) vehicles 

4. Using the special tools, remove the pinion flange.
Fig 3: Identifying Transmission Flange
Courtesy of FORD MOTOR CO.

All vehicles 

5. If removed, install the gearshift and the 4 shift housing bolts.
6. Remove the 19 extension housing bolts.
Fig 4: Locating Extension Housing Bolts
Courtesy of FORD MOTOR CO.
NOTE: Use a 1/8 in center punch to create a pilot hole in the plug before installing the tool. Using the Jet Plug Remover to make the pilot hole will damage the tool.
7. Using the special tool, remove the detent plugs and shift detent springs. Discard the detent plugs.
   • Lightly thread in the special tool so as not to damage the springs.
Fig 5: Removing Detent Plugs
Courtesy of FORD MOTOR CO.
8. Remove the main shift detent.
Fig 6: Main Shift Detent
Courtesy of FORD MOTOR CO.
9. Separate the main shift detent from the detent plunger.
   • Inspect the detent plunger for wear or damage. Install a new dent plunger as necessary.
Fig 7: Main Shift Detent & Detent Plunger
Courtesy of FORD MOTOR CO.
10. Remove the extension housing from the intermediate housing.
    • Using a soft-faced hammer, tap the extension housing lightly to break the gasket seal.
Fig 8: Removing Extension Housing From Intermediate Housing
Courtesy of FORD MOTOR CO.
11. Remove the intermediate housing-to-case bolts.
Fig 9: Intermediate Housing To Case Bolts
Courtesy of FORD MOTOR CO.
12. Using a suitable lifting device, a suitable chain and 2 S-hooks, lift the intermediate housing and gear assembly out of the main case.
    • Place the S-hooks in the intermediate housing where the 2 bolts were removed.
    • Place a protective cover or rag around the chain. This will make sure the low and reverse gears are not damaged during removal.
    • Lift the transmission 25 mm (1 in) off the ground. Using a soft-faced hammer, lightly tap the main housing to break the gasket seal.
Fig 10: Lifting Intermediate Housing & Gear Assembly
Courtesy of FORD MOTOR CO.
Fig 11: Covering Chains
Courtesy of FORD MOTOR CO.
13. Position the intermediate housing and gear assembly on the special tool.
    • Securely fasten the holding plate to a sturdy work bench.
Fig 12: Positioning Intermediate Housing & Gear Assembly On Special Tool (308-381)
Courtesy of FORD MOTOR CO.
14. Remove the 2 roll pins and the low/reverse/5th gear main shift rail driver.
    • Use a hammer and punch or an air hammer and roll pin remover.
Fig 13: Locating Roll Pins & Low/Reverse/5Th Gear Main Shift Rail Driver
Courtesy of FORD MOTOR CO.
NOTE: The shift finger is also the 1st/2nd and 3rd/4th rail driver.
15. Remove the lower roll pins.
    • Use a hammer and punch or an air hammer and roll pin remover to remove.
    • For vehicles equipped with a diesel engine, the shift finger is short. For vehicles equipped with a gas engine, the shift finger is long.
Fig 14: 1st/2nd And 3rd/4th Rail Driver & Pin
Courtesy of FORD MOTOR CO.
Fig 15: Roll Pin
Courtesy of FORD MOTOR CO.
16. Remove the lower shift finger and the main shift rail.
    1. Remove the lower shift finger.
       • Rotate the rail driver counterclockwise and pull outward to remove.
    2. Remove the main shift rail.
Fig 16: Lower Shift Finger & Main Shift Rail
Courtesy of FORD MOTOR CO.
17. Align the interlock plate into 2nd gear position, engage 2nd gear, then remove the two 5th gear shift fork roll pins.
    • Use a hammer and punch or an air hammer and roll pin remover to remove.
    • Discard the roll pins.
Fig 17: Using A Hammer & Punch Or An Air Hammer & Roll Pin Remover To Remove
Courtesy of FORD MOTOR CO.
18. Remove the 5th gear shift fork and shift rail.
    • Align the interlock plate into the 5th gear position. Remove the shift rail by tapping the shift fork with a soft-faced hammer while pulling up on the shift rail.
Fig 18: Removing Shift Rail By Tapping Shift Fork With A Soft-Faced Hammer While Pulling Up On Shift Rail
Courtesy of FORD MOTOR CO.
19. Remove the 2 low/reverse gear shift fork roll pins.
    • Use a hammer and punch or an air hammer and roll pin remover to remove.
    • Discard the roll pins.
Fig 19: Using A Hammer & Punch Or An Air Hammer & Roll Pin Remover To Remove
Courtesy of FORD MOTOR CO.
NOTE: Make sure the interlock plate is in the low/reverse gear position before removing. Shift the transmission into low gear.
20. Remove the low/reverse gear shift fork and shift rail.
    • Align the interlock plate into the low/reverse gear position. Remove the shift rail by tapping the shift fork with a soft-faced hammer while pulling up on the shift rail and fork.
Fig 20: Removing Shift Rail By Tapping Shift Fork With A Soft-Faced Hammer While Pulling Up On Shift Rail & Fork
Courtesy of FORD MOTOR CO.
21. Remove the shift rail detents, if necessary.
    • The shift rail detents can be difficult to remove. Using a heat gun, apply heat to the intermediate plate to ease removal.
Fig 21: Identifying Shift Rail Detents
Courtesy of FORD MOTOR CO.
22. On four wheel drive (4WD) vehicles, remove and discard the snap ring.
Fig 22: Snap Ring
Courtesy of FORD MOTOR CO.
23. Using the special tools, remove the mainshaft rear bearing, the output bearing thrust washer, mainshaft low gear, the mainshaft low gear bushing, the synchronizer assembly (low and reverse) and the mainshaft reverse gear.
Fig 23: Removing Mainshaft Rear Bearing, Output Bearing Thrust Washer, Mainshaft Low Gear, Mainshaft Low Gear Bushing, Synchronizer Assembly (Low And Reverse) & Mainshaft Reverse Gear
Courtesy of FORD MOTOR CO.
24. Remove the mainshaft rear bearing and the output bearing thrust washer from the low and reverse assembly.
    • Inspect the bearing for wear or damage. Install a new bearing as necessary.
    • Always install new bearings and cups as a set. Do not install one without the other.
Fig 24: Removing Mainshaft Rear Bearing & Output Bearing Thrust Washer From Low And Reverse Assembly
Courtesy of FORD MOTOR CO.
25. Remove the mainshaft needle bearings.
    • Inspect the bearings for wear or damage. Install new bearings as necessary.
Fig 25: Removing Mainshaft Needle Bearings
Courtesy of FORD MOTOR CO.
26. Remove the low gear from the low and reverse synchronizer assembly.
    • Inspect the low and reverse gears for wear or damage. Install new gears as necessary.
Fig 26: Removing Low Gear
Courtesy of FORD MOTOR CO.
27. Disassemble the low and reverse synchronizer assembly.
    • Inspect the components for wear or damage. Inspect the internal surface of the synchronizer rings for a contact pattern. The contact pattern should be the same on the entire internal circumference of the ring.
Fig 27: Exploded View Of Synchronizer Assembly
Courtesy of FORD MOTOR CO.
28. Check the clearance between the synchronizer ring and the gear.
    1. Place the synchronizer ring onto the synchronizer sliding sleeve. Position the synchronizer ring on the gear.
    2. Insert a feeler gauge and measure the clearance, while applying pressure and rotating the synchronizer ring. The clearance should be the same around the entire circumference.
       • Place the feeler gauge between the ring and gear. The ring has a raised section, inserting the feeler gauge past the teeth will give a incorrect reading.
       • If the clearance is less than 1.0 mm (0.04 in) for low or reverse gear, install a new synchronizer assembly, low gear or reverse gear to obtain correct specification.
Fig 28: Checking Synchronizer Ring & Gear Clearance (With Specifications)
Courtesy of FORD MOTOR CO.
29. Remove the mainshaft needle bearing.
Fig 29: Mainshaft Needle Bearing
Courtesy of FORD MOTOR CO.
30. For vehicles equipped with a diesel engine, remove the low gear thrust washer.
Fig 30: Low Gear Thrust Washer (6.0L)
Courtesy of FORD MOTOR CO.
31. Remove and discard the snap ring.
    • This is a selective fit snap ring.
Fig 31: Locating Snap Ring
Courtesy of FORD MOTOR CO.
32. Remove the countershaft rear thrust washer.
Fig 32: Countershaft Rear Thrust Washer
Courtesy of FORD MOTOR CO.
33. Remove 5th gear.
Fig 33: 5th Gear
Courtesy of FORD MOTOR CO.
34. Remove the countershaft needle bearing.
Fig 34: Countershaft Needle Bearing
Courtesy of FORD MOTOR CO.
35. Remove the interlock plate bolts.
Fig 35: Interlock Plate Bolts
Courtesy of FORD MOTOR CO.
NOTE: Do not use power tools to remove.
NOTE: Make sure the shift rails are not binding while pulling up on the intermediate housing.
36. Using the special tools, remove the countershaft bushing, the countershaft 5th gear synchronizer assembly and the intermediate housing.
    • When installing the Center Plate Legs, position them opposing one another.
    • Inspect the countershaft 5th gear synchronizer, countershaft bushing and the intermediate plate for wear or damage. Install new components as necessary.
Fig 36: Removing Countershaft Bushing, Countershaft 5Th Gear Synchronizer Assembly & Intermediate Housing
Courtesy of FORD MOTOR CO.
37. Disassemble the countershaft 5th gear synchronizer assembly.
    • Inspect the components for wear or damage. Inspect the internal surface of the synchronizer ring for a contact pattern. The contact pattern should be the same on the entire internal circumference of the ring.
Fig 37: Exploded View Of Synchronizer Assembly
Courtesy of FORD MOTOR CO.
38. Check the clearance between the synchronizer ring and the gear.
    1. Place the synchronizer ring onto the synchronizer sliding sleeve. Position the synchronizer ring on the gear.
    2. Insert a feeler gauge and measure the clearance, while applying pressure and rotating the synchronizer ring. The clearance should be the same around the entire circumference.
       • Place the feeler gauge between the ring and gear. The ring has a raised section. Inserting the feeler gauge past the teeth will give an incorrect reading.
       • If the clearance is less than 1.0 mm (0.04 in) for 5th gear, install a new synchronizer assembly or 5th gear to obtain correct specification.
Fig 38: Checking Synchronizer Ring & Gear Clearance (With Specifications)
Courtesy of FORD MOTOR CO.
CAUTION: To prevent damage, do not heat the mainshaft rear bearing, the countershaft or mainshaft rear thrust washer, the mainshaft bushing or the countershaft bushing higher than 150°C (300°F) maximum.
NOTE: Make sure the components are heated to 150°C (300°F) for reassembly.
39. New or original components should be heated in advance of the assembly procedure. Heating will ease the assembly process. Place the mainshaft rear bearing, the countershaft rear thrust washer, the countershaft bushing, the rear mainshaft bearing and the mainshaft low gear bushing into the Gear/Bearing Heater.
40. Remove the interlock plate, the 1st/2nd and 3rd/4th shift fork and shift rail assemblies.
Fig 39: 1st/2nd & 3rd/4th Shift Fork & Shift Rail Assemblies
Courtesy of FORD MOTOR CO.
41. Inspect all the shift fork pads and centers for wear or damage. Install new shift forks as necessary.
Fig 40: Checking Shift Fork Pads & Centers
Courtesy of FORD MOTOR CO.
CAUTION: To prevent damage, do not heat the bearings higher than 150°C (300°F) maximum.
42. Inspect the mainshaft middle bearing, the countershaft middle bearing and the bearing cups in the intermediate housing for wear or damage. Install new components as necessary.
    • Always install new bearings and cups as a set. Do not install one without the other.
    • The bearings should be heated to install. Place the bearings in the Gear/Bearing Heater.
43. Remove the countershaft rear bearing spacer.
Fig 41: Countershaft Rear Bearing Spacer
Courtesy of FORD MOTOR CO.
44. Remove the countershaft from the Gear Pack Assembly Fixture and set it aside.
Fig 42: Countershaft
Courtesy of FORD MOTOR CO.