Special Tool(s)

Courtesy of FORD MOTOR CO.	2 or 3 Jaw Puller 205-D027 (D80L-1013-A) or equivalent
Courtesy of FORD MOTOR CO.	Centerplate 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) or equivalent
Courtesy of FORD MOTOR CO.	Socket, Mainshaft Locknut (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: Locating Clutch Release Lever And Clutch Release Hub And Bearing

   Courtesy of FORD MOTOR CO.
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.
Fig 2: Locating Transmission On Floor With Output Flange Pointing Upward
Courtesy of FORD MOTOR CO.
3. Position the transmission on the floor with the output flange pointing upward.

   Rear Wheel Drive (RWD) vehicles 

4. Using the Drive Pinion Flange Holding Fixture and the Mainshaft Locknut (36-mm) Socket, remove the pinion flange.
   Fig 3: Removing Pinion Flange

   Courtesy of FORD MOTOR CO.

   All vehicles 

5. 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.
NOTE: Lightly thread in the Jet Plug Remover so as not to damage the springs.
Fig 5: Removing Detent Plugs And Shift Detent Springs
Courtesy of FORD MOTOR CO.
6. Using the Jet Plug Remover, remove the detent plugs and shift detent springs. Discard the detent plugs.
7. Remove the main shift detent.
   Fig 6: Locating Main Shift Detent

   Courtesy of FORD MOTOR CO.
8. 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: Locating Detent Plunger For Wear Or Damage

     Courtesy of FORD MOTOR CO.
9. 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: Locating Extension Housing From Intermediate Housing

     Courtesy of FORD MOTOR CO.
10. Remove the intermediate housing-to-case bolts.
    Fig 9: Locating Intermediate Housing To Case Bolts

    Courtesy of FORD MOTOR CO.
11. 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 (0.984 in) off the ground. Using a soft-faced hammer, lightly tap the main housing to break the gasket seal.
      Fig 10: Lifting Intermediate Housing And Gear Assembly Of Main Case

      Courtesy of FORD MOTOR CO.
      Fig 11: Locating Intermediate Housing And Gear Assembly Of Main Case

      Courtesy of FORD MOTOR CO.
12. Position the intermediate housing and gear assembly on the Gear Pack Fixture.
    • Securely fasten the holding plate to a sturdy work bench.
      Fig 12: Locating Intermediate Housing And Gear Assembly On Gear Pack Fixture

      Courtesy of FORD MOTOR CO.
13. 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

      Courtesy of FORD MOTOR CO.
NOTE: The shift finger is also the 1st/2nd and 3rd/4th rail driver.
14. 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: Locating Lower Roll Pins

      Courtesy of FORD MOTOR CO.
      Fig 15: Locating Lower Roll Pins

      Courtesy of FORD MOTOR CO.
15. 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: Locating Lower Shift Finger And Main Shift Rail

       Courtesy of FORD MOTOR CO.
16. 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: Locating Roll Pin

      Courtesy of FORD MOTOR CO.
17. 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 5Th Gear Shift Fork And Shift Rail

      Courtesy of FORD MOTOR CO.
18. 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: Locating Roll Pin

      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.
19. 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 Low/Reverse Gear Shift Fork And Shift Rail

      Courtesy of FORD MOTOR CO.
NOTE: The shift rail detents can be difficult to remove. Using a heat gun, apply heat to the intermediate plate to ease removal.
Fig 21: Locating Shift Rail Detents
Courtesy of FORD MOTOR CO.
20. Remove the shift rail detents, if necessary.
21. On Four-Wheel Drive (4WD) vehicles, remove and discard the snap ring.
    Fig 22: Locating Snap Ring

    Courtesy of FORD MOTOR CO.
22. Using the Shaft Protector Set and the 2 or 3 Jaw Puller, 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 And Mainshaft Reverse Gear

    Courtesy of FORD MOTOR CO.
23. 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.
      Fig 24: Locating Mainshaft Rear Bearing And Output Bearing Thrust Washer From Low And Reverse Assembly

      Courtesy of FORD MOTOR CO.
24. 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.
25. 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 From Low And Reverse Synchronizer Assembly

      Courtesy of FORD MOTOR CO.
26. 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: Disassembling Countershaft Fifth Gear Synchronizer Assembly

      Courtesy of FORD MOTOR CO.
27. 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 (0.039 in) for low or reverse gear, install a new synchronizer assembly, low gear or reverse gear to obtain correct specification.
         Fig 28: Checking Clearance Between Synchronizer Ring And Gear

         Courtesy of FORD MOTOR CO.
28. Remove the mainshaft needle bearing.
    Fig 29: Removing Mainshaft Needle Bearing

    Courtesy of FORD MOTOR CO.
29. For vehicles equipped with a diesel engine, remove the low gear thrust washer.
    Fig 30: Removing Low Gear Thrust Washer

    Courtesy of FORD MOTOR CO.
30. Remove and discard the snap ring.
    • This is a selective fit snap ring.
      Fig 31: Locating Snap Ring

      Courtesy of FORD MOTOR CO.
31. Remove the countershaft rear thrust washer.
    Fig 32: Locating Countershaft Rear Thrust Washer

    Courtesy of FORD MOTOR CO.
32. Remove the 5th gear.
    Fig 33: Locating 5th Gear

    Courtesy of FORD MOTOR CO.
33. Remove the countershaft needle bearing.
    Fig 34: Locating Countershaft Needle Bearing

    Courtesy of FORD MOTOR CO.
34. Remove the interlock plate bolts.
    Fig 35: Locating 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.
35. Using the Shaft Protector Set and Front Wheel Hub Remover/Installer with Centerplate Legs, remove the countershaft bushing, the countershaft 5th gear synchronizer assembly and the intermediate housing.
    • When installing the Centerplate 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: Inspecting Countershaft 5Th Gear Synchronizer, Countershaft Bushing And Intermediate Plate

      Courtesy of FORD MOTOR CO.
36. 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: Disassembling Countershaft Fifth Gear Synchronizer Assembly

      Courtesy of FORD MOTOR CO.
37. 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 (0.039 in) for 5th gear, install a new synchronizer assembly or 5th gear to obtain correct specification.
         Fig 38: Checking Clearance Between Synchronizer Ring And Gear

         Courtesy of FORD MOTOR CO.
NOTE: 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 (302°F) maximum.
NOTE: Make sure the components are heated to 150°C (302°F) for reassembly.
38. 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.
39. Remove the interlock plate, the 1st/2nd and 3rd/4th shift fork and shift rail assemblies.
    Fig 39: Removing Interlock Plate, 1st/2nd And 3rd/4th Shift Fork And Shift Rail Assemblies

    Courtesy of FORD MOTOR CO.
40. Inspect all the shift fork pads and centers for wear or damage. Install new shift forks as necessary.
    Fig 40: Locating Shift Fork Pads And Centers For Wear Or Damage

    Courtesy of FORD MOTOR CO.
NOTE: To prevent damage, do not heat the bearings higher than 150°C (302°F) maximum.
41. 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.
    • The bearings should be heated to install. Place the bearings in the Gear/Bearing Heater.
42. Remove the countershaft rear bearing spacer.
    Fig 41: Locating Countershaft Rear Bearing Spacer

    Courtesy of FORD MOTOR CO.
43. Remove the countershaft from the Gear Pack Fixture and set it aside.
    Fig 42: Removing Countershaft From Gear Pack Assembly Fixture

    Courtesy of FORD MOTOR CO.