Assembly

Transmission

1. Using a press, install front countershaft bearing onto countershaft cluster gear (7113) using Pinion Bearing Cone Replacer T57L-4621-B.






2. Position countershaft cluster gear in case (7005) .

CAUTION:Failure to properly support the countershaft cluster gear can result in permanent distortion of the case during bearing installation.






NOTE:Support the countershaft cluster gear using two pieces of 7mm (1/4-inch) bar stock.

3. Using a press and Cluster Gear Bearing Installer T83P-7025-AH and Remover Tube T77J-7025-B, install countershaft rear bearing (7025) to countershaft cluster gear.







4. Install rear countershaft bearing race onto countershaft cluster gear.






5. Install countershaft rear bearing retainer (7195) to transmission case with four 13mm bolts.

NOTE:This should be done initially without any shims installed. Tighten bolts to 15-27 Nm (11-20 lb-ft).






6. Measure end play using Dial Indicator with Bracketry TOOL-4201-C or equivalent.

Remove countershaft rear bearing retainer and install necessary shim(s) between countershaft rear bearing retainer and rear countershaft bearing race. Verify end play is within 0.0254-0.127mm (0.001-0.005 inch). After installing countershaft rear bearing retainer , bend tabs on countershaft rear bearing retainer over the four retaining bolts.






7. Position reverse idler gear and bushing (7141) in case with shift lever groove facing rear of case.

Install reverse idler gear shaft (7140) and reverse gear overtravel stop (7E397) . Install reverse idler gear shaft from rear of case and position reverse gear overtravel stop between reverse idler gear and bushing and reverse idler gear shaft .






8. Using a 5mm (3/16-inch) pin punch, install reverse idler gear shaft roll pin.







9. If removed, apply Pipe Sealant with Teflon D8AZ-19554-A or equivalent meeting Ford specification WSK-M2G350-AZ and ESR-M18P7-A to shift rail rear pin threads. Install anchor pin and tighten to 8-15 Nm (6-11 lb-ft).

10. Align reverse gearshift lever (7K002) , reverse shift fork (7231) and reverse positioning spring as shown.







11. Lower assembly into case and install looped end of reverse positioning spring onto anchor pin.







12. Position reverse idler gear and bushing into the NEUTRAL position and align reverse shift fork onto reverse idler gear and bushing . Once aligned, push downward on reverse shift fork until fully engaged into reverse idler gear and bushing.

NOTE:Observe reverse positioning spring rotation. Reverse positioning spring should rotate counterclockwise into its installed position.







13. Install output and fifth gear drive shaft (7061) assembly.







NOTE:The following step is not required for Mustang Cobra.

14. Coat the 15 bearings, spacer or sleeve (7072) and snap ring with Multi-Purpose Grease D0AZ-19584-AA or equivalent meeting Ford specification ESR-M1C159-A and ESB-M1C93-A. Install components in input shaft (7017).






15. Align notches in synchronizer blocking ring (7107) with synchronizer hub inserts (7A044) in three/four synchronizer (7124) and install synchronizer blocking ring .







16. Install input shaft . Align flat on synchronizer teeth with countershaft cluster gear before installing input shaft.

NOTE:Ensure three/four synchronizer blocking ring is still in proper position.






17. Install output shaft rear bearing cup (7169) in main drive gear bearing retainer (7050).

NOTE:Do not install end play shims at this point.






18. Temporarily, install main drive gear bearing retainer with narrow or smaller notch facing upward. Do not apply sealant to the main drive gear bearing retainer at this point.

19. Tighten retaining bolts to 15-27 Nm (11-20 lb-ft).






20. Install output shaft rear bearing cup. If necessary, tap output shaft rear bearing cup into position using a plastic-tipped hammer.






21. Install reverse gear shift rail (7240) into transmission case by aligning ball stud with slot in case and aligning reverse gear shift rail with reverse shift fork. Once ball stud enters case , rotate reverse gear shift rail clockwise and push in reverse gear shift rail until ball aligns with reverse gearshift lever . Rotate reverse gear shift rail counterclockwise until ball stud fully engages reverse gearshift lever.






22. Install fifth speed cluster gear (7144), synchronizer and gear shifter fork (7230) as an assembly.







23. Install fifth-speed cluster gear synchronizer and speedometer gear snap ring (7064).






NOTE:Alignment tab on reverse brake ring must engage the alignment slot in the extension housing (7A039) when installing extension housing to prevent component damage.

24. Apply Pipe Sealant with Teflon� D8AZ-19554-A or equivalent meeting Ford specification WSK-M2G350-AZ and ESR-M18P7-A to the shift rail rear pin threads and install the shift rail rear pin.

Tighten shift rail rear pin to 34-47 Nm (25-35 lb-ft) using a T55 Torx� driver. Apply Pipe Sealant with Teflon� D8AZ-19554-A or equivalent meeting Ford specification WSK-M2G350-AZ and ESR-M18P7-A to the backup lamp switch (15520) and install using a 22mm socket. Tighten to 27-47 Nm (20-35 lb-ft).






25. Using needlenose pliers, install reverse idler gear retaining ring (7156) on shift rail rear pin.






26. Install speedometer drive gear (17285).

NOTE:The tab on the speedometer drive gear retaining clip (17B336) engages a hole in the output and fifth gear drive shaft .






CAUTION: Do not apply silicone sealer to top of transmission case surface under any circumstances, as sealant could fall into transmission and affect operation.

27. Apply 3.2mm (1/8 inch) bead of Silicone Rubber D6AZ-19562-AA or BA or equivalent meeting Ford specification ESB-M4G92-A and ESE-M4G195-A to case cover (7222) assembly.

NOTE:Ensure all synchronizers are in the NEUTRAL position and that the gear shifter forks in the case cover are in the NEUTRAL position.
Position case cover to filler plug side of transmission (7003) and lower into position until gear shifter forks engage synchronizers . Continue lowering case cover and move into position to engage reverse gearshift lever.

28. Install case cover retaining bolts. Tighten case cover retaining bolts to 8-15 Nm (6-11 lb-ft).






29. Apply a 3.2mm (1/8-inch) bead of Silicone Rubber D6AZ-19562-AA or BA or equivalent meeting Ford specification ESB-M4G92-A and ESE-M4G195-A on the extension housing mating surface. Apply Silicone Rubber D6AZ-19562-AA or BA or equivalent meeting Ford specification ESB-M4G92-A and ESE-M4G195-A to the gearshift tube bushing (7L278) and install funnel to extension housing (7A039).






30. Coat shifter interlock spring (7234) with petroleum jelly and install in gearshift offset lever (7F018) . Lubricate detent plate and install detent ball in neutral position on plate. Position gearshift offset lever in extension housing with shifter interlock spring over detent ball.






31. Slide gearshift offset lever and extension housing into position as an assembly.

NOTE:Make sure lubrication funnel engages into fifth-gear synchronizer.






32. Press downward on gearshift offset lever to compress shifter interlock spring and push gearshift offset lever and extension housing into position.






33. Install extension housing retaining bolts. Tighten to 47-61 Nm (30-45 lb-ft).







34. Using a suitable pin punch, align the hole in gearshift shaft and offset lever (7358) with hole in gearshift offset lever and install roll pin.

Install gearshift shaft bushing (7K453) in gearshift offset lever .

NOTE:Output shaft geartrain end play must be checked and adjusted at this point.






35. Check output shaft geartrain end play as follows:

a. Rotate transmission to the vertical position with extension housing facing up.

b. Mount Dial Indicator with Bracketry TOOL-4201-C or equivalent on the extension housing with the indicator stylus contacting the output and fifth gear drive shaft.

c. Rotate the input shaft and output and fifth gear drive shafts. Zero the dial indicator.






d. Using a wood block, push upward on the input shaft and note the dial indicator reading.

NOTE:A shim must be installed that is the thickness of the dial indicator reading. This will provide zero end play.

CAUTION: Thickest shim must be installed closest to the front bearing cup.

CAUTION: Although zero end play is the ideal end play specification, a plus or minus .050mm (0.002 inch) is an acceptable tolerance. Do not overload the bearings with too thick a shim.






36. Rotate transmission to the horizontal position and remove the main drive gear bearing retainer. Remove bearing race from main drive gear bearing retainer and install the necessary shim(s).






37. CAUTION: The sealer must not cover the notch in the main drive gear bearing retainer.

Apply a 3.2mm (1/8 inch) bead of Silicone Rubber D6AZ-19562-AA or BA or equivalent meeting Ford specification ESB-M4G92-A and ESE-M4G195-A to main drive gear bearing retainer.






Install main drive gear bearing retainer with narrow or smaller notch facing upward, and tighten retaining bolts to 15-27 Nm (11-20 lb-ft). Check end play.

38. Apply a 3.2mm (1/8 inch) bead of Silicone Rubber D6AZ-19562-AA or BA or equivalent meeting Ford specification ESB-M4G92-A and ESE-M4G195-A on the turret cover.






39. Position shift control selector lever and housing (7210) on the extension housing and tighten the retaining bolts to 17-20 Nm (12-15 lb-ft).






40. Install and tighten drain plug to 17-29 Nm (12-22 lb-ft).