Assembly

Special Tools:

1. Position the input shaft over the input shaft pocket bearing and position the assembly in the Gear Pack Holding Fixture.





2. Position the countershaft assembly on the holding fixture.





3. Position the shift rails and forks into the Shift Rod Support in the same position from which they were removed.





4. Position the shift rails and forks onto the mainshaft assembly so that gear shifter forks engage the sliding sleeves of the synchronizers.





5. Position the gear selector interlock plate on the shift rails and engage it in the grooves on the main shift rail.





6. Install the spacer if required.
7. Position the extension housing in the Bench-Mounted Holding Fixture.





8. Secure the main shaft/counter shaft assembly to the Gear Pack Holding Fixture with an endless lifting sling. Position the assembly into the extension housing.





9. If equipped, install the companion flange and locknut. Tighten the locknut finger tight at this time.





10. Remove the Shift Rod Support.





11. Remove the endless lifting sling.





12. Install the bolts.





13. Engage the teeth of the reverse idler gear with the reverse gear. Install the reverse idler gear shaft. Align the threaded holes in the shaft with the bolt holes in the extension housing.
14. Install the sealing ring and idler shaft bolt. Finger-tighten the bolt at this time.





15. Install the main shift rail.





16. CAUTION: The tapered roller bearing preload should be adjusted if either the case or extension housing, countershaft cluster gear, main shaft, input shaft, or a bearing has been replaced. If the tapered roller bearings on the main shaft, input shaft, or countershaft cluster gear have to be adjusted, do not apply Gasket Maker E2AZ-19562-B or equivalent meeting Ford specification WSK-M2G348-A50.

CAUTION: Do not use a silicone sealing compound.

NOTE: Do not wait longer than ten minutes to tighten all 17 bolts, due to the rapid curing time of the sealant.

If the tapered roller bearings do not have to be adjusted, thinly coat the sealing surface of the extension housing with Gasket Maker E2AZ-19562-B or equivalent meeting Ford specification WSK-M2G348-A5.





17. CAUTION: Make sure that the shift rail bearings do not obstruct entry of the shift rails.

CAUTION: Be careful that the input shaft does not damage the input shaft seal and extension housing seal. Also be careful that the oil baffle is not bent when the case is positioned over the input shaft.

Carefully place the case over the main shaft and countershaft cluster gear and shift rails until it rests on its mating surface on the extension housing. It may be necessary to push the 5th-reverse shift rail inward to clear the inner surfaces of the case.





18. Install the 17 case to extension housing bolts.





19. Tighten the reverse idler bolts.
20. Rotate the transmission so the input shaft is pointing down.





21. Install the rear seal.
22. Tighten the output shaft locknut.





23. Install the PTO cover and gasket.





24. CAUTION: The procedure must be followed exactly to make sure that the interlock function operates properly.

NOTE: Make sure that the interlock plate and shifter interlock spring do not drop into the case.

Position the 5th-reverse gear interlock plate into its installed position. Place the gasket over the mating surface of the shift control housing in the case.

Make sure that the stop plate moves freely and that the gasket does not interfere with it. The interlock plate must be in a position which is lower than the gasket so that the plate may move freely.

Unloaded length of shifter interlock spring is 35.5 mm (1.398 inch) minimum.

Place the shifter interlock spring above the nose in the interlock plate and move both parts into their installed positions.





25. CAUTION: Do not force the shift lever to shift into reverse. Damage to the interlock components could occur.

Install the shift lever housing. Make sure the gasket is positioned correctly.

Check the functioning of the interlock:
^ Temporarily install the shift lever. The nose on the shift lever located just above the ball must point toward the interlock plate. Install spring washers and tighten screws to 22 Nm (16 ft. lbs.).
^ The shift lever cannot be shifted between fifth and reverse if the interlock was properly installed.
^ Once proper installation of the interlock is confirmed, remove the shift lever.





26. CAUTION: Do not strike the detent spring plug in the center as such an action can cause the detent spring plug to cave in, which will result in leakage.

Install the three detent springs and spring plugs.





27. Install the backup lamp switch.