Assembly

Special Tools:

1. Position the countershaft cluster gear in the case.





2. CAUTION: Failure to correctly support the case will result in the permanent distortion of the case during bearing race installation.

Install the rear countershaft bearing
1 Position two pieces of 7mm (1/4 inch) bar stock between the countershaft and the case.
2 Using a press and the special tools, install the rear countershaft bearing cone.





3. Install the rear countershaft bearing cup.





4. Note: This step should be carried out initially without the shims in place.

Install the countershaft rear bearing retainer.





5. Measure the countershaft end play.
^ Using the special tool, measure the countershaft end play.
^ Remove the countershaft rear bearing retainer and install the necessary shim(s). End play is 0.0254 - 0.127 mm (0.001 - 0.005 inch).
^ Install the countershaft rear bearing retainer and bolts.
^ After installing the bolts, bend the tab or the retainer.





6. Position the reverse idler gear and bushing in the case with the shift lever groove facing the rear of the case. Install the reverse idler shaft and the reverse gear over-travel stop.





7. Install the reverse idler shaft roll pin.





8. Install the shift rail rear pin.
^ Apply Pipe Sealant with Teflon D8AZ-19554-A or equivalent meeting Ford specification WSK-M2G350-A2 to the shift rail rear pin.
^ Install the shift rail rear pin.





9. Align the reverse gearshift lever, the reverse shift fork and the reverse positioning spring.





10. Lower the assembly into the case. Install the looped end of the reverse positioning spring around the shift rail rear pin.





11. Note: Observe the reverse positioning spring rotation. The spring should rotate counterclockwise into its installed position.

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





12. Install the output shaft assembly.





13. Install the bearings, spacer and snap ring.
^ Coat the 15 bearings, the spacer, the thrust bearing and the thrust washer with Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specification ESB-M1C93.
^ Install the bearings, spacer and snap ring into the input shaft.





14. Install the synchronizer blocking ring.
^ Align the notches in the synchronizer blocking ring and the synchronizer hub inserts.





15. Note: Make sure the synchronizer blocking ring is still in position.

Align the flat on the synchronizer teeth with the countershaft cluster gear. Install the input shaft.





16. Note: Do not install the end play shims at this time.

Note: Do not apply sealant to the main drive gear retainer at this time.

Install the output shaft bearing cup into the main drive gear bearing retainer.





17. Install the main drive gear bearing retainer with the notch facing upward.





18. Install the output shaft rear bearing cup.





19. Install the reverse shift rail into the case by aligning the ball stud in the slot in the case and aligning the reverse gear shift rail with the reverse shift fork. Once the ball stud enters the case, rotate the reverse gear shift rail until the ball aligns with the reverse gear shift lever. Rotate the reverse gear shift rail counterclockwise until the ball stud fully engages the reverse gear shift lever.





20. Install the fifth speed cluster gear, the synchronizer assembly and the gear shifter fork reverse as an assembly.





21. CAUTION: The alignment tab on the brake ring must engage the alignment slot in the extension housing when installing the extension housing to prevent component damage.

Install the synchronizer blocking ring, brake ring, retainer and fifth gear synchronizer snap ring.





22. Note: Before installing the shift rail rear pin, make sure the reverse gear shift rail ball stud is fully engaged with the reverse gear shift lever.

Install the shift rail rear pin.
^ Apply Pipe Sealant with Teflon(D D8AZ-19554-A or equivalent meeting Ford specifications WSK-M2G350-A2 and MSR-M18P7-A
^ Install the shift rail rear pin.





23. Install the backup lamp switch.
^ Apply Pipe Sealant with Teflon D8AZ- 19554-A or equivalent meeting Ford specifications WSK-M2G350-A2 and MSR-M18P7-A
^ Install the backup lamp switch.





24. Install the reverse idler gear retaining ring.





25. Install the VSS tone wheel.
^ Install the VSS tone wheel.
^ Install the snap ring.

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

Apply a 3.2 mm (1/8 inch) bead of Silicone Rubber (clear) D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A to the case cover.





27. Note: Make sure all the synchronizers are in the NEUTRAL position and the gear shifter forks in the cover are in the NEUTRAL position.
Position the cover toward the filler plug side of the transmission and lower until the gear shifter forks engage the synchronizers. Continue to lower the cover and move it into position to engage the reverse gearshift lever.





28. Install the bolts





29. Note: The alignment tab on the brake ring must align with the alignment slot in the extension housing to prevent component damage.

Install the oil-pick-up funnel into the extension housing.
^ Apply a 3.2mm (1/8 inch) bead of Silicone Rubber (clear) D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A to the extension housing mating surface.
^ Apply Silicone Rubber (clear) D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A to the oil-pick-up funnel
^ Install the oil-pick-up funnel.





30. Position the gearshift offset lever in the extension housing.
^ Coat the shifter interlock spring with petroleum jelly and install it into the gearshift offset lever.
^ Lubricate the detent plate and install the detent ball into the neutral position on the plate.
^ Position the gearshift offset lever in the extension housing with the gear shift interlock spring over the detent ball.





31. Note: Make sure the lubrication funnel engages into the fifth gear synchronizer and the alignment tap on the brake ring engages the alignment slot in the extension housing.

Slide the gearshift offset lever and the extension housing into place as an assembly.





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





33. Install the bolts.





34. Install the roll pin.





35. Measure the output shaft end play.
6 Position the transmission in a vertical position.
^ Install the special tools.
^ Push up on the input shaft and record the dial indicator reading.





36. CAUTION: The thickest shim must be installed closest to the front bearing cup for necessary cup support.

CAUTION: Although zero end play is the ideal, end play up to 0.05mm (0.002 inch) is an acceptable tolerance Do not overload the bearings with a shim that is too thick as damage may occur.

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

Rotate the transmission to the horizontal position and remove the main drive gear bearing retainer. Remove the bearing race 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 (clear) D6AZ-19562-AA or equivalent meeting Ford specification to the main drive gear bearing retainer.





38. Install the main drive gear bearing retainer and the four bolts.
39. Apply a 3.2mrn (1/8 inch) bead of Silicone Rubber (clear) D6AZ-19562-AA or equivalent meeting Ford specification on the shift housing cover.





40. Install the gearshift lever on the extension housing.





41. Using the special tool, install the rear oil seal.





42. Install the case plug.