Assembly

Special Tools:

1. Install the countershaft.





2. Position the input shaft.





3. NOTE: Make sure the fourth gear synchronizer blocking ring is in place.

Install the output shaft.
4. Mate the input shaft and output shaft together.





5. Install the countershaft pilot bearing.





6. Install the output shaft rear bearing.





7. NOTE: Install the rear bearing retainer with the arrow pointing to the top of the case.

Install the rear bearing retainer.
1 Position the rear bearing retainer.
2 Install the bolts.

NOTE: If any related parts (such as the output shaft, bearing, etc.) have been replaced, perform shim thickness selective procedure.





8. Use (A) Bell Housing Seal Replacer to install the (B) front cover oil baffle.
9. Position the transmission with the bell housing facing up.





10. Use (B) Depth Micrometer to measure dimension (A) (input shaft bearing race depth).
- Record dimension (A) on line 2 of the selective shim equation chart.





11. Use (A) Depth Micrometer to measure dimension (B) (front bearing retainer depth).
- Record dimension (B) on line 1 of the selective shim equation chart.

Output Shaft Shim Selective Chart:

12. Select the proper output shaft shim.





13. Use (A) Depth Micrometer to measure dimension (C) (countershaft bearing).
- Record dimension (C) on line 1 of the countershaft spacer equation chart.





14. Use (A) Depth Micrometer to measure dimension (D) (countershaft bearing retainer depth).
- Record dimension (D) on line 2 of the countershaft spacer equation chart.

Countershaft Spacer Selective Chart (Part 1 Of 2):

15. Select the proper countershaft spacer.





16. NOTE: If necessary, apply a light coat of grease to the countershaft spacer, shim and fluid baffle.

Position the (A) bearing shim, (B) fluid baffle and (C) countershaft spacer onto the front bearing retainer.





17. NOTE: To prevent damage to the fluid seal lip during assembly, tape the input shaft splines.

Install the front bearing retainer.
1 Position the front bearing retainer.
2 Install the bolts.





18. Position the fluid passage.





19. Install the fluid passage bolt.





20. Install the output shaft fifth speed gear.





21. Install the (A) race and (B) fifth speed gear split bearing on the countershaft.





22. Install the countershaft fifth speed gear.





23. Install the counter lever shaft assembly.
1 Position the counter lever shaft and plate.
2 Install the counter lever shaft bolt.





24. Install the 5th reverse shift lever.
1 Position the 5th reverse shift lever.
2 Install the 5th reverse shift retaining ring.





25. Install the countershaft fifth gear synchronizer blocking ring.





26. NOTE: The reference mark on the synchronizer sleeve must face toward the reverse gear.

Install the (A) fifth/reverse shift rail, (B) shift fork and (C) synchronizer.





27. Install the fifth/reverse shift rail bolt.





28. Install the synchronizer split washer.





29. Check clutch hub end play.

Split Washer Select Chart:

- If clutch hub end play is not within specification, select and install the correct split washer.





30. Install the countershaft reverse gear.
1 Install the countershaft reverse gear.
2 Install the two countershaft reverse gear bearings.
3 Install the reverse synchronizer blocking ring.





31. Measure the countershaft reverse gear end play.

Thrust Washer Select Chart:

- Install the thrust washer and hold it against the shoulder on the countershaft while checking end play.
- Determine the correct thrust washer to obtain correct end play.





32. Install the output shaft spacer.





33. Install the output shaft reverse gear.





34. Install the reverse idler gear and bushing.





35. NOTE: Apply Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A to reverse idler shaft bolt threads.

Install the reverse idler shaft bolt.





36. Use (A) Gear Installing Spacer (4x2 models only), Gear Installing Spacer, (B) Shaft Collar (4x2) or Shaft Collar (4x4), (C) Shaft Sleeve Replacer, (D) Remover/Replacer Tube, (E) nut and (F) washer to install the (G) output shaft rear bearing.





37. Install the (A) thrust washer and (B) countershaft rear bearing.





38. Lock the transmission into first and third gear.





39. Use Mainshaft Locknut Wrench to install a new output shaft rear bearing locknut.





40. Install a new countershaft locknut.





41. Use (A) Mainshaft Locknut Staking Tool to stake the (B) output shaft locknut and (C) countershaft locknut.





42. Install the speedometer drive gear.
1 Position the speedometer drive gear.
2 Install the snap ring.
43. Apply a small bead of silicone rubber to the extension housing mating surface.
- Use Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A to case surface.





44. Install the extension housing.
1 Position extension housing.
2 Install the bolts.





45. Use (A) Extension Housing Seal Replacer to install a new (B) extension housing seal.





46. Place the synchronizer sleeves in neutral.
47. Apply a small bead of silicone rubber to the case cover mating surface.
- Use Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A.





48. Install the case cover.
1 Position the case cover.
2 Install the bolts.





49. Install the (D) wiring harness and connect the (C) backup lamp switch connector, (B) VSS connector, and (A) HEGO sensor connectors.