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Manual Transaxle - T5OD: Assembly: Transmission: Material

MATERIAL SPECIFICATIONS

Item Specification
Motorcraft MERCON(R) Multi-Purpose (ATF) Transmission Fluid
XT -2-QDX		 MERCON(R)
Pipe Sealant with Teflon(R)
D8AZ-19554-A		 ESR-M18P7-A
Multi -Purpose Grease
D0AZ-19554-AA		 ESB-M1C93 -B
Clear Silicone Rubber
D6AZ-19562-AA		 ESB-M4G92-A
Motorcraft Premium Long Life Grease
XG -1-C		 ESA-M1C75 -B
  1. Soak the blocking rings in transmission fluid for ten minutes.
  2. Position the countershaft cluster gear in the case.
    Fig 1: Positioning Countershaft Cluster Gear In Case
    G03402585Courtesy of FORD MOTOR CO.
    3. CAUTION: Failure to correctly support the case during bearing installation will result in permanent distortion of the case.
  3. Using a the special tools and a press, install the rear countershaft bearing assembly.
    1. Position two 6.35 mm (0.25 in) pieces of bar stock between the countershaft and the case.
    2. Using a the special tools and a press, install the rear countershaft bearing assembly.
      Fig 2: Installing Rear Countershaft Bearing Assembly
      G03402586Courtesy of FORD MOTOR CO.
  4. Install the rear countershaft bearing race.
    Fig 3: Installing Rear Countershaft Bearing Race
    G03402587Courtesy of FORD MOTOR CO.
    5. NOTE: Do not install the shims at this time.
    Fig 4: Installing Countershaft Rear Bearing Retainer
    G03402588Courtesy of FORD MOTOR CO.
  5. Install the countershaft rear bearing retainer.
  6. Using the special tool, measure the countershaft cluster gear end play.
    • If the end play is not within the specifications, remove the countershaft rear bearing retainer, and install the necessary thickness shim(s). Reinstall the countershaft rear bearing retainer, and recheck the end play.
    • Bend the tabs of the countershaft rear bearing retainer over the bolts when the end play adjustment is complete.
      Fig 5: Measuring Countershaft Cluster Gear End Play
      G03402589Courtesy of FORD MOTOR CO.
  7. 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 gear shaft and the reverse gear overtravel stop.
    Fig 6: Installing Reverse Idler Gear Shaft And Reverse Gear Overtravel Stop
    G03402590Courtesy of FORD MOTOR CO.
  8. Install the pin.
    Fig 7: Installing Pin
    G03402591Courtesy of FORD MOTOR CO.
  9. Align the reverse gearshift lever, the reverse shift fork, and the reverse positioning spring.
    Fig 8: Aligning Reverse Gearshift Lever, Reverse Shift Fork And Reverse Positioning Spring
    G03402592Courtesy of FORD MOTOR CO.
    10. NOTE: Observe the reverse positioning spring rotation. The spring must rotate counterclockwise into its installed position.
  10. Install the reverse shift fork.
    • Place the reverse idler gear and bushing into the NEUTRAL position. Align the reverse shift fork and the reverse idler gear and bushing. Push downward on the reverse shift fork until fully engaged into the reverse idler gear and bushing.
      Fig 9: Installing Reverse Shift Fork
      G03402593Courtesy of FORD MOTOR CO.
  11. Install the output shaft assembly.
    Fig 10: Installing Output Shaft Assembly
    G03402594Courtesy of FORD MOTOR CO.
    12. NOTE: Position the looped end of the reverse positioning spring around the shift lever reverse pin.
    Fig 11: Installing Shift Lever Reverse Pin
    G03402595Courtesy of FORD MOTOR CO.
  12. Apply pipe sealant to the shift lever reverse pin threads and install the pin.
  13. Install the roller bearings, the input shaft bearing spacer, the thrust bearing, and the thrust washer.
    • Coat the 15 bearings, the spacer, the thrust bearing, and the thrust washer with grease.
      Fig 12: Installing Roller Bearings, Input Shaft Bearing Spacer, Thrust Bearing And Thrust Washer
      G03402596Courtesy of FORD MOTOR CO.
    14. NOTE: If not done so previously, soak the blocking ring in MERCON(R) Multi-Purpose ATF Transmission Fluid XT-2-QDX or equivalent for ten minutes.
  14. Install the fourth speed synchronizer blocking ring.
    • Align the notches in the synchronizer blocking ring and the synchronizer hub inserts.
      Fig 13: Installing Fourth Speed Synchronizer Blocking Ring
      G03402597Courtesy of FORD MOTOR CO.
    15. NOTE: Verify that the fourth speed synchronizer blocking ring is still in position.
    Fig 14: Installing Input Shaft
    G03402598Courtesy of FORD MOTOR CO.
  15. Align the flat on the fourth gear clutching teeth with the countershaft cluster gear and install the input shaft.
    16. NOTE: Do not install the end play shims at this time.
    NOTE: Do not apply sealant to the input shaft bearing retainer at this time.
    Fig 15: Installing Bearing Race In Bearing Retainer
    G03402599Courtesy of FORD MOTOR CO.
  16. Install the bearing race in the bearing retainer.
  17. Install the input shaft bearing retainer with the notch facing upward.
    Fig 16: Installing Input Shaft Bearing Retainer With Notch
    G03402600Courtesy of FORD MOTOR CO.
  18. Install the bolts.
    Fig 17: Installing Bolts
    G03402601Courtesy of FORD MOTOR CO.
  19. Install the output shaft rear bearing cup.
    Fig 18: Installing Output Shaft Rear Bearing Cup
    G03402602Courtesy of FORD MOTOR CO.
  20. Install the reverse gear shift rail.
    • Align the ball stud with the slot in the case and align 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 gearshift lever. Rotate the reverse gear shift rail counterclockwise until the ball stud fully engages the reverse gearshift lever.
      Fig 19: Installing Reverse Gear Shift Rail
      G03402603Courtesy of FORD MOTOR CO.
    21. NOTE: If not done so previously, soak the blocking ring in transmission fluid for ten minutes.
    Fig 20: Installing Fifth Speed Cluster Gear, Synchronizer Blocking Ring And Shifter Fork
    G03402604Courtesy of FORD MOTOR CO.
  21. Install the fifth speed cluster gear, the synchronizer blocking ring, the synchronizer assembly, and the fifth gear shifter fork as an assembly.
    22. CAUTION: To prevent component damage when installing the extension housing (7A039), the alignment tab on the reverse brake ring (7M000) must engage the alignment slot in the extension housing.
    NOTE: If not done so previously, soak the blocking ring in transmission fluid for ten minutes.
    Fig 21: Installing Synchronizer Blocking Ring, Reverse Brake Ring And Retaining Snap Ring
    G03402605Courtesy of FORD MOTOR CO.
  22. Install the synchronizer blocking ring, the reverse brake ring, the thrust washer, and the fifth speed synchronizer retaining snap ring.
  23. Apply pipe sealant to the reversing lamp switch threads and install the switch.
    Fig 22: Installing Reversing Lamp Switch
    G03402606Courtesy of FORD MOTOR CO.
  24. Install the reverse gearshift lever retaining clip.
    Fig 23: Installing Reverse Gearshift Lever Retaining Clip
    G03402607Courtesy of FORD MOTOR CO.
  25. Install the output shaft speed wheel and the snap ring.
    Fig 24: Installing Output Shaft Speed Wheel And Snap Ring
    G03402608Courtesy of FORD MOTOR CO.
    26. CAUTION: Do not under any circumstance apply silicone sealant to the top of the transmission case. The sealant could fall into the transmission and affect transmission operation.
  26. Apply a 3.2-mm (1/8-in) bead of silicone rubber to the sealing surface on the case cover.
    27. NOTE: Verify that all of the synchronizers are in the NEUTRAL position and the gear shifter forks in the cover are in the NEUTRAL position.
  27. Install the case cover.
    • Position the cover toward the filler plug side of the transmission and lower it until the gear shifter forks engage the synchronizers. Continue to lower the cover and move it into position to engage the reverse gearshift lever.
      Fig 25: Installing Case Cover
      G03402609Courtesy of FORD MOTOR CO.
  28. Install the bolts.
    Fig 26: Installing Bolts
    G03402610Courtesy of FORD MOTOR CO.
  29. Apply a 3.2-mm (1/8-in) bead of silicone rubber to the sealing surface on the extension housing.
    Fig 27: Locating Sealant Applying Point
    G03402611Courtesy of FORD MOTOR CO.
  30. Install the detent ball, the shifter detent spring, and the gearshift offset lever.
    1. Coat the shifter detent spring with petroleum jelly and install it in the gearshift offset lever.
    2. Lubricate the detent plate and install the detent ball in the neutral position on the plate.
    3. Position the gearshift offset lever in the extension housing with the gear shift interlock spring over the detent ball.
      Fig 28: Installing Detent Ball, Shifter Detent Spring And Gearshift Offset Lever
      G03402612Courtesy of FORD MOTOR CO.
    31. CAUTION: To prevent component damage, the alignment tab on the reverse brake ring must align with the alignment slot in the extension housing.
    NOTE: Verify that the oil pick-up funnel engages the fifth gear synchronizer.
    Fig 29: Installing Gearshift Offset Lever And Extension Housing
    G03402613Courtesy of FORD MOTOR CO.
    Fig 30: [Installing Shifter Interlock Spring]
    G03402614Courtesy of FORD MOTOR CO.
  31. Slide the gearshift offset lever and the extension housing into place as an assembly. Press downward on the gearshift offset lever to compress the shifter interlock spring and push the gearshift offset lever and extension housing into place.
  32. Install the identification tag and the bolts.
    Fig 31: Installing Identification Tag
    G03402615Courtesy of FORD MOTOR CO.
  33. Install the split pin and the gearshift shaft bushing.
    Fig 32: Installing Split Pin And Gearshift Shaft Bushing
    G03402616Courtesy of FORD MOTOR CO.
  34. Using the special tools, measure the output shaft end play.
    1. Place the transmission in a vertical position.
    2. Install the special tool.
    3. Push upward on the input shaft and record the dial indicator reading.
      Fig 33: Measuring Output Shaft End Play
      G03402617Courtesy of FORD MOTOR CO.
    35. CAUTION: Install the thickest shim closest to the front bearing cup to provide support for the cup.
    CAUTION: Although zero end play is the ideal, end play up to .05 mm (0.002 in) is an acceptable tolerance. Do not overload the bearings with a shim that is too thick as damage may occur.
    NOTE: Select a shim with a thickness equal to the dial indicator reading. This will provide zero end play.
    Fig 34: Removing Bearing Race
    G03402618Courtesy of FORD MOTOR CO.
  35. Rotate the transmission to the horizontal position and remove the input shaft bearing retainer. Remove the bearing race and install the necessary shim(s).
    36. CAUTION: Do not cover the notch in the input shaft bearing retainer with sealer.
  36. Apply a 3.2-mm (1/8-inch) bead of silicone rubber to the sealing surface on the input shaft bearing retainer.
  37. Install the input shaft bearing retainer and the four bolts.
    Fig 35: Installing Input Shaft Bearing Retainer
    G03402619Courtesy of FORD MOTOR CO.
  38. Apply a 3.2-mm (1/8-inch) bead of silicone rubber to the sealing surface on the gearshift lever.
  39. Install the gearshift lever.
    Fig 36: Installing Gearshift Lever
    G03402620Courtesy of FORD MOTOR CO.
  40. Using the special tool, install the extension housing fluid seal.
    Fig 37: Installing Extension Housing Fluid Seal
    G03402621Courtesy of FORD MOTOR CO.
  41. Install the case plug.
    Fig 38: Installing Case Plug
    G03402622Courtesy of FORD MOTOR CO.
    42. NOTE: Before installing the transmission, the ball stud, clutch release lever and the input shaft must be cleaned and lubricated with grease.
  42. Install the clutch release hub and bearing and the clutch release lever. For additional information, refer to CLUTCHES .
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