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Transmission Shift Components - Disassembled View

WARNING: This page is about a different car, the 2010 Ford Pickup, 2010 Ford F550 Super Duty, 2010 Ford F450 Super Duty, and 2010 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Exploded View Of Transmission Shift Components
G06778992Courtesy of FORD MOTOR CO.
ITEM DESCRIPTION CHART

Item Part Number Description
1 7210 Shift lever (lower)
2 7C371 Shift lever blocks
3 7277 Shift lever boot
4 - Shift housing bolt (4 required)
5 7203 Shift housing
6 7811 Shift finger
7 7B096 Roll pins (double) (14 required)
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 plug
16 7N120 Detent spring
17 7247 Shift rail detent
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
NOTE: Transmission fluid usage:
  • Gas engines use MERCON® V Automatic Transmission Fluid.
  • Diesel engines use Motorcraft® Full Synthetic Fluid.
    NOTE: Do not reassemble the transmission dry. Apply lubricant throughout the assembly procedure or damage to the components can occur.
  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.
    Fig 2: Aligning Index-Mark Countershaft In Relation To Oil Pump Slot (1 Of 2)
    G06778993Courtesy of FORD MOTOR CO.
    Fig 3: Aligning Index-Mark Countershaft In Relation To Oil Pump Slot (2 Of 2)
    G06778994Courtesy of FORD MOTOR CO.
  3. Position the countershaft to the mainshaft on the Gear Pack Fixture.
    Fig 4: Positioning Countershaft To Mainshaft On Gear Pack Fixture
    G06778995Courtesy of FORD MOTOR CO.
  4. Install the countershaft rear bearing spacer.
    • The countershaft rear bearing spacer can be installed either way.
      Fig 5: Installing Countershaft Rear Bearing Spacer
      G06778996Courtesy 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.
      Fig 6: Installing First/Second, Third/Fourth Shift Fork And Shift Rail Assemblies
      G06778997Courtesy of FORD MOTOR CO.
  6. Install the interlock plate.
    • The stamped part numbers on the interlock plate must face toward the input shaft.
      Fig 7: Locating Interlock Plate
      G06778998Courtesy 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.
      Fig 8: Installing Intermediate Housing On Mainshaft, Countershaft, And Shift Rails
      G06778999Courtesy of FORD MOTOR CO.
  8. Install the interlock plate bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 9: Locating Interlock Plate Bolts
      G06779000Courtesy of FORD MOTOR CO.
  9. Assemble the 5th gear synchronizer assembly.
    Fig 10: Assembling 5Th Gear Synchronizer Assembly
    G06779001Courtesy 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.
      Fig 11: Installing 5Th Gear Synchronizer Assembly
      G06779002Courtesy of FORD MOTOR CO.
    11. NOTE: To prevent damage, do not heat the countershaft bushing higher than 150°C (302°F) maximum.
    Fig 12: Installing Countershaft Bushing
    G06779003Courtesy of FORD MOTOR CO.
  11. Remove the countershaft bushing from the Gear/Bearing Heater, then install the countershaft bushing.
    12. NOTE: Allow the countershaft bushing to cool for 2-4 minutes before installing the countershaft needle bearing.
    Fig 13: Installing Countershaft Needle Bearing
    G06779004Courtesy of FORD MOTOR CO.
  12. Install the countershaft needle bearing.
  13. Install the 5th gear.
    Fig 14: Locating 5Th Gear
    G06779005Courtesy 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.
      Fig 15: Locating Countershaft Rear Thrust Washer And Snap Ring
      G06779006Courtesy of FORD MOTOR CO.
  15. For vehicles equipped with a diesel engine, install the low gear thrust washer.
    Fig 16: Locating Low Gear Thrust Washer
    G06779007Courtesy of FORD MOTOR CO.
  16. Install the 2 mainshaft low gear needle bearings.
    Fig 17: Locating Mainshaft Low Gear Needle Bearings
    G06779008Courtesy of FORD MOTOR CO.
  17. Install the low gear.
    Fig 18: Locating Low Gear
    G06779009Courtesy 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.
      Fig 19: Locating Low And Reverse Synchronizer Assembly And Synchronizer Ring
      G06779010Courtesy of FORD MOTOR CO.
    19. NOTE: To prevent damage, do not heat the reverse gear bushing higher than 150°C (302°F) maximum.
    Fig 20: Installing Mainshaft Bushing
    G06779011Courtesy of FORD MOTOR CO.
  19. Remove the mainshaft reverse gear bushing from the Gear/Bearing Heater, then install the mainshaft bushing.
    20. NOTE: Allow the mainshaft reverse gear bushing to cool for 2-4 minutes before installing mainshaft needle bearing.
    Fig 21: Locating Mainshaft Needle Bearing
    G06779012Courtesy of FORD MOTOR CO.
  20. Install the mainshaft needle bearing.
  21. Install the reverse gear. Pull the synchronizer sliding sleeve into the neutral position.
    Fig 22: Locating Reverse Gear
    G06779013Courtesy of FORD MOTOR CO.
    22. NOTE: To prevent damage, do not heat the output bearing thrust washer higher than 150°C (302°F) maximum.
    Fig 23: Installing Output Bearing Thrust Washer
    G06779014Courtesy of FORD MOTOR CO.
  22. Remove the output bearing thrust washer from the Gear/Bearing Heater, then using the Thrust Washer Bearing Cup Remover/Installer, install the output bearing thrust washer.
    23. NOTE: To prevent damage, do not heat the rear mainshaft output bearing higher than 150°C (302°F) maximum.
    Fig 24: Installing Rear Mainshaft Output Bearing
    G06779015Courtesy of FORD MOTOR CO.
  23. Remove the mainshaft output bearing from the Gear/Bearing Heater, then using the Thrust Washer Bearing Cup Remover/Installer, install the rear mainshaft output bearing.
  24. Using the Dial Indicator Gauge with Holding Fixture and the Clutch Housing Gauge, check the axial gear clearance at 5th gear.
    • If not within specifications, disassemble and reinspect.
      Fig 25: Checking Axial Gear Clearance At 5Th Gear
      G06779016Courtesy of FORD MOTOR CO.
  25. Using the Dial Indicator Gauge with Holding Fixture and the Clutch Housing Gauge, check the axial gear clearance at low gear.
    • If not within specifications, disassemble and reinspect.
      Fig 26: Checking Axial Gear Clearance At Low Gear
      G06779017Courtesy of FORD MOTOR CO.
  26. Using the Dial Indicator Gauge with Holding Fixture and the Clutch Housing Gauge, check the axial gear clearance at reverse gear.
    • If not within specifications, disassemble and reinspect.
      Fig 27: Checking Axial Gear Clearance At Reverse Gear
      G06779018Courtesy of FORD MOTOR CO.
    27. 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.
      Fig 28: Locating Snap Ring
      G06778821Courtesy of FORD MOTOR CO.
    28. 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.
    Fig 29: Installing Fifth Gear Shift Fork And Shift Rail
    G06779020Courtesy of FORD MOTOR CO.
  28. Install the 5th gear shift fork and the shift rail.
  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.
      Fig 30: Locating Roll Pin Hole With Shift Fork
      G06779021Courtesy of FORD MOTOR CO.
    30. 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.
    Fig 31: Installing Low/Reverse Gear Shift Fork And Shift Rail
    G06779022Courtesy of FORD MOTOR CO.
  30. Install the low/reverse gear shift fork and the shift rail.
  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.
      Fig 32: Installing Double Roll Pin In Lower Hole
      G06779023Courtesy 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.
      Fig 33: Installing Four Shift Detent Springs And Detent Plugs
      G06779024Courtesy 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.
      Fig 34: Installing Main Shift Rail
      G06779025Courtesy 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.
      Fig 35: Installing Small Roll Pin
      G06779026Courtesy 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.
      Fig 36: Installing Main Shift Rail Driver And Large Roll Pin
      G06779027Courtesy of FORD MOTOR CO.
    36. 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 (1.968-3.976 in), 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 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.
      Fig 37: Lifting Intermediate Housing And Gear Assembly Into Case
      G06778809Courtesy of FORD MOTOR CO.
  38. Install the intermediate housing-to-case bolts.
    • Tighten to 23 Nm (17 lb-ft).
      Fig 38: Locating Intermediate Housing To Case Bolts
      G06778808Courtesy of FORD MOTOR CO.
  39. Install the Dial Indicator Gauge with Holding Fixture and the Clutch Housing Gauge to measure countershaft clearance.
    • Mount the Holding Fixture 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 Gauge.
      Fig 39: Measuring Countershaft Clearance
      G06779030Courtesy of FORD MOTOR CO.
    40. NOTE: The Front Wheel Hub Remover/Installer is installed on the Power Take-Off (PTO) opening.
  40. Using the Front Wheel Hub Remover/Installer, measure for countershaft clearance.
    • Lift up on the 3rd gear counter.
    • Observe the Dial Indicator Gauge reading.
    • Add preload specification 0.02 mm (0.0007 in) and 0.09 mm (0.003 in) to the Dial Indicator Gauge reading to determine shim thickness range. Countershaft clearance + 0.02 mm (0.0007 in) Preload = Shim size. Countershaft clearance + 0.09 mm (0.003 in) Preload = Shim size. Choose the shim between the calculated values for the correct preload.
      Fig 40: Measuring Countershaft Clearance
      G06779031Courtesy of FORD MOTOR CO.
  41. Install the Dial Indicator Gauge with Holding Fixture and the Clutch Housing Gauge to measure mainshaft clearance.
    • Mount the Holding Fixture 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 Gauge.
      Fig 41: Measuring Mainshaft Clearance
      G06779032Courtesy of FORD MOTOR CO.
  42. Lifting up on the mainshaft, measure the mainshaft clearance.
    • Lift up on the low gear.
    • Observe the Dial Indicator Gauge reading.
    • Add preload specification 0.02 mm (0.0007 in) and 0.09 mm (0.003 in) to the Dial Indicator Gauge 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 (0.0007 in) Preload = Shim size. Mainshaft clearance (-) the thickness of the oil dam + 0.09 mm (0.003 in) Preload = Shim size. Choose the shim between the calculated values for the correct preload.
      Fig 42: Measuring Mainshaft Clearance
      G06779033Courtesy of FORD MOTOR CO.
  43. Remove the special tools, then remove the intermediate housing-to-case bolts.
    Fig 43: Locating Intermediate Housing To Case Bolts
    G06778808Courtesy 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.
      Fig 44: Lifting Intermediate Housing And Gear Assembly Into Case
      G06778809Courtesy of FORD MOTOR CO.
  45. Using the Front Wheel Hub Remover/Installer and the Input Shaft Bearing Cup Remover, remove the input shaft bearing cup.
    Fig 45: Removing Input Shaft Bearing Cup
    G06778924Courtesy of FORD MOTOR CO.
  46. Using the Slide Hammer with the Bearing Cup Remover, remove the countershaft bearing cup.
    Fig 46: Removing Countershaft Bearing Cup
    G06778920Courtesy of FORD MOTOR CO.
    47. 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 Input Shaft Bearing Cup Installer with the Handle, install the input shaft bearing cup.
    • Using the clearance measurement plus the preload, select the appropriate shim and input shaft oil dam bearing ring.
      Fig 47: Installing Input Shaft Bearing Cup
      G06778934Courtesy of FORD MOTOR CO.
    48. NOTE: Use a Heat Gun on the case bearing cup area to aid installation.
  48. Install the new shim, then using the Centerplate Front Bearing Cup Installer and the Handle, install the countershaft bearing cup.
    • Using the clearance measurement plus the preload, select the appropriate shim.
      Fig 48: Installing Countershaft Bearing Cup
      G06779039Courtesy of FORD MOTOR CO.
    49. NOTE: Do not use a silicone sealing compound or damage to the components can occur.
    NOTE: Use an oil stone or sanding block to clean the intermediate plate and main case mating surfaces.
    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 (1.968-3.976 in), 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.
      Fig 49: Installing Intermediate Housing And Gear Assembly Into Case
      G06778809Courtesy of FORD MOTOR CO.
  51. Install the intermediate housing-to-case bolts.
    • Apply threadlock and sealer to the intermediate housing-to-case bolts.
    • Tighten to 23 Nm (17 lb-ft).
      Fig 50: Locating Intermediate Housing To Case Bolts
      G06778808Courtesy of FORD MOTOR CO.
    52. 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-to-case bolts.
    • Tighten to 23 Nm (17 lb-ft).
      Fig 51: Installing Extension Housing And Extension Housing-To-Case Bolts
      G06779042Courtesy 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).
      Fig 52: Locating Bolt And Main Shift Detent
      G06779043Courtesy of FORD MOTOR CO.
    54. NOTE: Tighten the bolts in a cross pattern.
  54. Apply threadlock and sealer to the threads of the PTO  cover plate bolts. Install a new gasket and the PTO  cover.
    • Tighten to 38 Nm (28 lb-ft).
      Fig 53: Locating PTO Cover Plate Bolts
      G06779044Courtesy of FORD MOTOR CO.
    55. 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 Input Shaft Oil Seal Installer, install a new input oil seal.
    • Coat the inner diameter of the new input oil seal with manual transmission fluid.
      Fig 54: Installing Input Oil Seal
      G06779045Courtesy 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).
      Fig 55: Locating Guide Tube Bolts
      G06779046Courtesy 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.
      Fig 56: Locating Clutch Release Lever And Clutch Release Hub And Bearing
      G06778800Courtesy of FORD MOTOR CO.
  58. Using the Output Shaft Oil Seal Installer (4x2) 308-382 for RWD  or Output Shaft Oil Seal Installer (4x4) 308-383 for 4WD  , install a new output oil seal.
    Fig 57: Installing RWD Output Shaft Oil Seal
    G06778748Courtesy of FORD MOTOR CO.
    Fig 58: Installing 4WD Output Oil Seal
    G06779049Courtesy of FORD MOTOR CO.
    59. NOTE: This step is for 2-Wheel Drive (2WD) vehicles only.
  59. Apply threadlock 262 to the threads of the transmission flange locknut. Using the Drive Pinion Flange Holding Fixture and the Mainshaft Locknut (36-mm) Socket, install the transmission flange and a new output flange locknut.
    • Tighten to 330 Nm (244 lb-ft).
      Fig 59: Installing Transmission Flange And Output Flange Locknut
      G06779050Courtesy of FORD MOTOR CO.
  60. Install the shift housing and the 4 shift housing-to-case bolts.
    • Tighten to 23 Nm (17 lb-ft).
    • Shift the transmission through all gears to verify gears shift correctly.
      Fig 60: Locating Shift Housing And Shift Housing-To-Case Bolts
      G06778754Courtesy of FORD MOTOR CO.
  61. Check transmission preload. Shift the transmission into reverse and rotate the mainshaft.
    • Drag torque should be 2-8 Nm (18-70 lb-in).
  62. Remove the shift housing-to-case bolts and the shift housing for installation.
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