Transmission

Transmission - FWD

WARNING: Before beginning any service procedure, REFER to Safety Warnings . Failure to follow this instruction may result in serious personal injury.

Special Tool(s)










Material(s)






Exploded View










Disassembly

1. Clean the transmission exterior with solvent and dry with compressed air.

2. Clean all parts removed with solvent and dry with compressed air.

3. Remove and discard the clutch slave cylinder.





4. Install 307-003 (T57L-500-B).





5. NOTE: Position the selector mechanism in the NEUTRAL position.
Remove the 6 selector mechanism-to-transmission bolts and the selector mechanism.





6. Remove the VSS (Vehicle Speed Sensor).





7. NOTE: Rotate the transmission with the input shaft pointing upward.
Remove the 16 transmission case bolts.





8. NOTICE: Take care not to damage the transmission case.

Carefully pry the transmission clutch housing from the transmission case.





9. Remove the transmission clutch housing.





10. Remove the differential assembly.





11. Remove and clean the magnetic disc.





12. Remove the shift rails and the 1st and 2nd gear shift fork.





13. Remove the shift forks.

1. Move the 5th and reverse gear selector fork to the side.

2. Rotate the 3rd and 4th gear selector fork and remove, then remove the 5th and reverse gear selector fork.






14. Remove the 2 reverse gear idler shaft bolts.





15. Lift out the input and the output shaft from transmission case together.





16. Remove the reverse idler gear retainer, then lift out the reverse idler gear.





17. Remove the following:

1. Upper thrust washer

2. Reverse idler gear

3. Reverse idler gear bearing

4. Lower thrust washer






18. Remove and discard the halfshaft oil seals.





19. Using 300-MASHG501AE , heat the case bearing cup area. Using 308-001 (T58L-101-B) , remove the differential bearing race from the transmission clutch housing.





20. Using 300-MASHG501AE , heat the case bearing cup area. Using 308-001 (T58L-101-B) , remove the output shaft bearing race from the transmission clutch housing.





21. Using 300-MASHG501AE , heat the case bearing cup area. Using 308-001 (T58L-101-B) , remove the input shaft bearing race from the transmission clutch housing.





22. Remove the shims.










23. Using 300-MASHG501AE , heat the case bearing area. Using 308-001 (T58L-101-B) , remove the input shaft bearing race from the transmission case.





24. Using 300-MASHG501AE , heat the case bearing area. Using 308-001 (T58L-101-B) , remove the output shaft bearing race from the transmission case.






25. Using 300-MASHG501AE , heat the case bearing area. Using 308-001 (T58L-101-B) , remove the differential bearing race from the transmission case.





26. NOTE: Only remove the reverse gear idler shaft if there is evidence of damage or leaks.
Remove the 3 reverse gear idler shaft plate bolts and the reverse gear idler shaft plate.





27. NOTE: Only remove the reverse gear idler shaft if there is evidence of damage or leaks.
Using a brass drift, remove the reverse gear idler shaft.





Assembly

1. Apply Motorcraft(R) Full Synthetic Manual Transmission Fluid throughout the assembly procedure. Lubricate all bearings, gears and synchronizers with Motorcraft(R) Full Synthetic Manual Transmission Fluid.

2. Attach the transmission case to 307-003 (T57L-500-B).

3. Apply Gasket Maker to the reverse gear idler shaft plate mating face. Install the reverse gear idler shaft plate and the 3 reverse gear idler shaft plate bolts.
- Tighten to 24 Nm (18 lb-ft).

4. Install the reverse gear idler shaft.

5. NOTE: If new output shaft bearings were installed, install new output shaft bearing cups. Always install new bearings and cups in sets.

NOTE: Use 300-MASHG501AE on the case bearing cup area to aid installation.
Using 308-221 (T94P-7025-BH) and 205-D055 (D81L-4000-A) , install the output shaft bearing cup in the transmission case.





6. NOTE: If new input shaft bearings were installed, install new input shaft bearing cups. Always install new bearings and cups in sets.

NOTE: Use 300-MASHG501AE on the case bearing cup area to aid installation.
Using a driver, install the input shaft bearing cup in the transmission case.





7. NOTE: If new differential bearings were installed, install new differential bearing cups. Always install new bearings and cups in sets.

NOTE: Use 300-MASHG501AE on the case bearing cup area to aid installation.
Using a driver, install the differential bearing cup in the transmission case.





8. NOTE: If new input shaft bearings were installed, install new input shaft bearing cups. Always install new bearings and cups in sets.

NOTE: Use 300-MASHG501AE on the case bearing cup area to aid installation.
Install a 1 mm (0.0394 in) shim. Using a driver, install the input shaft bearing cup in the transmission clutch housing.





9. NOTE: If new output shaft bearings were installed, install new output shaft bearing cups. Always install new bearings and cups in sets.

NOTE: Use 300-MASHG501AE on the case bearing cup area to aid installation.
Install a 1 mm (0.0394 in) shim. Using a driver, install the output shaft bearing cup in the transmission clutch housing.





10. NOTE: If new differential bearings were installed, install new differential bearing cups. Always install new bearings and cups in sets.

NOTE: Use 300-MASHG501AE on the case bearing cup area to aid installation.
Install a 1.1 mm (0.0433 in) shim. Using a driver, install the differential bearing cup in the transmission clutch housing.





11. Engage the 4th gear synchronizer on the input shaft.





12. Assemble the input and output shafts together and put them in the transmission case as an assembly.





13. Install the differential assembly.





14. NOTE: Do not apply Gasket Maker at this time.
Position the transmission clutch housing and install the 16 transmission case bolts uniformly.
- Tighten to 32 Nm (24 lb-ft).





15. Using 308-224 (T94P-7025-EH) , rotate the input shaft to seat the bearings.





16. Install 100-002 (TOOL-4201-C) to measure input shaft end play. Make sure the dial indicator is off center on the end of the input shaft. Zero the dial indicator.





17. Measure the input shaft end play using 100-002 (TOOL-4201-C).

1. Using a lever, lift up on the input shaft.

2. Observe and record the dial indicator reading.

- Carry out the measurement 3 times and calculate the average measurement. Example: 0.22 mm (0.0087 in) + 0.23 mm (0.0091 in) + 0.21 mm (0.0083 in) divided by 3 = 0.22 mm (0.0087 in).






18. Install 308-216 (T94P-4451-AH) to the transmission then install 100-002 (TOOL-4201-C) to measure output shaft end play. Position 100-002 (TOOL-4201-C) on the 4th gear. Zero the dial indicator.





19. Measure the output shaft end play.

- Using a lever, lift up on the output shaft. Note the resulting measurement, for example, 0.32 mm (0.0126 in).

- Carry out the measurement 3 times and calculate the average measurement. Observe and record the dial indicator reading. Example: 0.32 mm (0.0126 in) + 0.34 mm (0.0134 in) + 0.33 mm (0.013 in) divided by 3 = 0.33 mm (0.013 in).






20. Install 308-224 (T94P-7025-EH) and 100-002 (TOOL-4201-C). Prepare the differential for measuring.

- Rotate the output shaft and at the same time press downward. Set up 100-002 (TOOL-4201-C) and set it to zero. Carry out the measurement 3 times and calculate the average measurement.






21. Using 303-350 (T89P-6565-A) and 308-S217 (T94P-4451-BH) , measure the differential end play. Observe and record the dial indicator reading.





22. Using the measurements, select the appropriate shims for the differential, input shaft and the output shaft. REFER to General Specifications .

23. NOTE: Use 300-MASHG501AE on the case bearing cup area to aid removal.
Remove the output shaft bearing cup, the input shaft bearing cup, the differential bearing cup and the shims from the transmission clutch housing.

24. NOTE: Use 300-MASHG501AE on the case bearing cup area to aid installation.
Install the appropriate shims and the bearing cups.

1. Install the appropriate shims.

2. Install the bearing cups.






25. Apply a light coat of petroleum jelly, then install the lower thrust washer. The tab on the washer faces downward.





26. Install the reverse idler gear and the upper thrust washer. Do not install the bearing at this time. Install the gear with the oil grooves facing downward.





27. NOTE: Position the 4th gear selector ring into the neutral position.
Push the reverse idler gear away from the output shaft bearing cup. Install the input shaft and the output shaft as an assembly. Position both shafts into the bearing cups and align with the reverse idler gear.





28. Install the reverse idler gear needle bearing.





29. Install the reverse idler gear retainer.





30. Install the shift forks.

1. Install the 5th/reverse gear selector fork and position it to the side.

2. Install the 3rd/4th gear selector fork.

3. Install the 1st/2nd gear selector fork.






31. Install the shift rails. When installed, the selector rods are the same height.





32. Install the differential assembly.





33. Install the magnetic disc.





34. Using Thread Sealant with PTFE, install the reverse gear idler shaft bolts.
- Tighten to 34 Nm (25 lb-ft).





35. Clean the mating surfaces of the selector mechanism and the transmission case. Apply a bead of Gasket Maker to the sealing surface of the transmission case. Install the selector mechanism and the 6 selector mechanism-to-transmission bolts.
- Tighten to 23 Nm (17 lb-ft).





36. Clean the mating surfaces of the transmission case. Apply a bead of Gasket Maker to the sealing surface on the transmission case. Install the transmission clutch housing.





37. NOTE: The transmission must not be turned over to tighten the bolts.

NOTE: Do not wait longer than 10 minutes to tighten the bolts due to the rapid cure time of the sealant.
Install the 16 transmission case bolts.
- Tighten to 32 Nm (24 lb-ft).





38. Install the VSS (Vehicle Speed Sensor).
- Tighten to 10 Nm (89 lb-in).





39. Using 308-222 (T94P-7025-CH) and 205-153 (T80T-4000-W) , install new differential oil seals.





40. NOTICE: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled on a painted or plastic surface, wash the affected area immediately with cold water.

NOTICE: Using adhesive tape, cover the input shaft splines to prevent damage to the input shaft oil seal.

NOTE: Do not apply grease on any area of the clutch slave cylinder.
Install a new clutch slave cylinder with a new seal. Install the 3 clutch slave cylinder bolts.

- Make sure the seal is correctly installed or it may cause starter failure.
- Tighten to 10 Nm (89 lb-in).