LEMON Manuals: Even more car manuals for everyone
Home >> Lincoln >> 2003 >> Aviator AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 577 (Manual Transmission) >> Assembly >> Transmission >> Assembly

Section 577 (Manual Transmission): Assembly: Transmission: Assembly

WARNING: This page is about a different car, the 2004 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the countershaft cluster gear.
    Fig 1: Installing Countershaft Cluster Gear
    G03276296Courtesy of FORD MOTOR CO.
  2. Position the input shaft.
    Fig 2: Positioning Input Shaft
    G03276297Courtesy of FORD MOTOR CO.
    3. NOTE: Make sure the fourth gear synchronizer blocking ring is in place.
    Fig 3: Installing Output Shaft
    G03276298Courtesy of FORD MOTOR CO.
  3. Install the output shaft.
  4. Mate the input shaft and output shaft together.
  5. Install the countershaft pilot bearings on both ends.
    Fig 4: Installing Countershaft Pilot Bearings
    G03276299Courtesy of FORD MOTOR CO.
  6. Install the output shaft rear bearing and input shaft bearing.
    Fig 5: Installing Output Shaft Rear Bearing And Input Shaft Bearing
    G03276300Courtesy of FORD MOTOR CO.
    7. NOTE: Install the rear bearing retainer with the arrow pointing to the top of the case.
  7. Install the rear bearing retainer.
    • Position the rear bearing retainer.
    • Install the bolts.
      Fig 6: Installing Rear Bearing Retainer
      G03276301Courtesy of FORD MOTOR CO.
    8. NOTE: If any related parts (such as the output shaft and bearings) have been installed new, carry out the shim thickness selective procedure.
    Fig 7: Installing Front Cover Oil Baffle
    G03276302Courtesy of FORD MOTOR CO.
  8. Using the special tool, install the front cover oil baffle.
  9. Position the transmission with the bell housing facing up.
  10. Using the special tool, measure the input shaft bearing race depth.
    • Record the reading on line 2 of the selective shim equation chart.
      Fig 8: Measuring Input Shaft Bearing Race Depth
      G03276303Courtesy of FORD MOTOR CO.
  11. Using the special tool, measure the front bearing retainer depth.
    • Record the reading on line 1 of the selective shim equation chart.
      Fig 9: Measuring Front Bearing Retainer Depth
      G03276304Courtesy of FORD MOTOR CO.
  12. Calculate and select the correct output shaft shim. Refer to the Output Shaft Shim Selective Chart.
    SELECTIVE SHIM EQUATION CHART

    Step Measurement mm (in)
    Line 1 (Dimension B)  
    Line 2 (Dimension A)  
    Line 3 (Subtract line 2 from line 1)  
    OUTPUT SHAFT SHIM SELECTIVE CHART

    Total From Line 3 mm (in) Part Number Thickness mm (in)
    2.75-2.85 (0.108-0.112) E8TZ-7029-C 2.7 (0.106)
    2.85-2.95 (0.112-0.116) E8TZ-7029-D 2.8 (0.110)
    2.95-3.05 (0.116-0.120) E8TZ-7029-E 2.9 (0.114)
    3.05-3.15 (0.120-0.124) E8TZ-7029-F 3.0 (0.118)
    3.15-3.25 (0.124-0.127) E8TZ-7029-G 3.1 (0.122)
    3.25-3.35 (0.127-0.131) E8TZ-7029-H 3.2 (0.125)
    3.35-3.45 (0.131-0.135) E8TZ-7029-J 3.3 (0.129)
    3.45-3.55 (0.135-0.139) E8TZ-7029-K 3.4 (0.133)
    3.55-3.65 (0.139-0.143) E8TZ-7029-L 3.5 (0.137)
    3.65-3.75 (0.143-0.147) E8TZ-7029-M 3.6 (0.141)
    3.75-3.85 (0.147-0.151) E8TZ-7029-N 3.7 (0.145)
    3.85-3.95 (0.151-0.155) E8TZ-7029-P 3.8 (0.149)
    3.95-4.05 (0.155-0.159) E8TZ-7029-R 3.9 (0.153)
    4.05-4.15 (0.159-0.163) E8TZ-7029-A 4.0 (0.157)
    4.15-4.25 (0.163-0.167) E8TZ-7029-B 4.1 (0.161)
  13. Using the special tool, measure the countershaft bearing depth.
    • Record the reading on line 1 of the countershaft spacer equation chart.
      Fig 10: Measuring Countershaft Bearing Depth
      G03276305Courtesy of FORD MOTOR CO.
  14. Using the special tool, measure the countershaft bearing retainer depth.
    • Record the reading on line 2 of the countershaft spacer equation chart.
      Fig 11: Measuring Countershaft Bearing Retainer Depth
      G03276306Courtesy of FORD MOTOR CO.
  15. Calculate and select the correct countershaft spacer. Refer to the COUNTERSHAFT SPACER SELECTIVE CHART .
    COUNTERSHAFT SPACER EQUATION CHART

    Step Measurement mm (in)
    Line 1 (Dimension C)  
    Line 2 (Dimension D)  
    Line 3 (add line 1 and line 2)  
    COUNTERSHAFT SPACER SELECTIVE CHART

    Total From Line 3 mm (in) Part Number Thickness mm (in)
    2.45-2.55 (0.096-0.100) E8TZ-7C434-A 2.3 (0.090)
    2.55-2.65 (0.100-0.104) E8TZ-7C434-B 2.4 (0.094)
    2.65-2.75 (0.104-0.108) E8TZ-7C434-C 2.5 (0.098)
    2.75-2.85 (0.108-0.112) E8TZ-7C434-D 2.6 (0.102)
    2.85-2.95 (0.112-0.116) E8TZ-7C434-E 2.7 (0.106)
    2.95-3.05 (0.116-0.120) E8TZ-7C434-F 2.8 (0.110)
    3.05-3.15 (0.120-0.124) E8TZ-7C434-G 2.9 (0.114)
    3.15-3.25 (0.124-0.127) E8TZ-7C434-H 3.0 (0.118)
    3.25-3.35 (0.127-0.132) E8TZ-7C434-J 3.1 (0.122)
    16. NOTE: If necessary, apply a light coat of grease to the countershaft spacer, shim and fluid baffle.
  16. Position the bearing shim, the fluid baffle, and the countershaft spacer onto the front bearing retainer.
    • Using Gasket Maker F8AZ-19B508-AB or equivalent meeting Ford specification WSKM2G348-A5, apply a thin coat to the sealing surface of the case and the front bearing retainer.
      Fig 12: Positioning Bearing Shim, Fluid Baffle, And Countershaft Spacer
      G03276307Courtesy of FORD MOTOR CO.
    17. NOTE: To prevent damage to the fluid seal lip during assembly, tape the input shaft splines.
    Fig 13: Installing Front Bearing Retainer
    G03276308Courtesy of FORD MOTOR CO.
  17. Install the front bearing retainer.
  18. Position the oil cooler tube.
    Fig 14: Positioning Oil Cooler Tube
    G03276309Courtesy of FORD MOTOR CO.
  19. Install the front oil cooler tube bolt.
    Fig 15: Installing Front Oil Cooler Tube Bolt
    G03276310Courtesy of FORD MOTOR CO.
  20. Install the output shaft fifth gear.
    Fig 16: Installing Output Shaft Fifth Gear
    G03276311Courtesy of FORD MOTOR CO.
  21. Install the locking ball.
  22. Install the race and the fifth gear split needle bearing on the countershaft.
    Fig 17: Installing Race And Fifth Gear Split Needle Bearing On Countershaft
    G03276312Courtesy of FORD MOTOR CO.
  23. Install the countershaft fifth gear.
    Fig 18: Installing Countershaft Fifth Gear
    G03276313Courtesy of FORD MOTOR CO.
  24. Install the fifth/reverse shift lever through the case.
    Fig 19: Installing Fifth/Reverse Shift Lever Through Case
    G03276314Courtesy of FORD MOTOR CO.
  25. Install the counter lever shaft assembly.
    • Install the plate with the arrow pointing downward. The chamfer points upward on the shaft assembly.
      Fig 20: Installing Counter Lever Shaft Assembly
      G03276315Courtesy of FORD MOTOR CO.
  26. Install the countershaft fifth gear synchronizer blocking ring.
    Fig 21: Installing Countershaft Fifth Gear Synchronizer Blocking Ring
    G03276316Courtesy of FORD MOTOR CO.
    27. NOTE: The reference mark on the synchronizer sleeve must face toward the reverse gear.
    Fig 22: Installing Fifth/Reverse Shift Rail, Shift Fork, And Synchronizer
    G03276317Courtesy of FORD MOTOR CO.
  27. Install the fifth/reverse shift rail, the shift fork, and the synchronizer as an assembly.
  28. Install the fifth/reverse gear shift rail bolt.
    Fig 23: Installing Fifth/Reverse Gear Shift Rail Bolt
    G03276318Courtesy of FORD MOTOR CO.
  29. Install the synchronizer split washer.
    Fig 24: Installing Synchronizer Split Washer
    G03276319Courtesy of FORD MOTOR CO.
  30. Using a feeler gauge, check the clutch hub end play.
    • If the clutch hub end play is not within specification, select and install the correct split washer.
      SPLIT WASHER SELECT CHART

      Part Number Thickness mm (in)
      E8TZ-7R482-A 3.0 (0.118)
      E8TZ-7R482-B 3.1 (0.122)
      E8TZ-7R482-C 3.2 (0.125)
      E8TZ-7R482-D 3.3 (0.129)
      E8TZ-7R482-E 3.4 (0.133)
      E8TZ-7R482-F 3.05 (0.120)
      E8TZ-7R482-G 3.15 (0.124)
      E8TZ-7R482-H 3.25 (0.127)
      E8TZ-7R482-J 3.35 (0.131)
      E8TZ-7R482-K 3.45 (0.135)
      E8TZ-7R482-L 3.50 (0.137)
      Fig 25: Checking Clutch Hub End Play
      G03276320Courtesy of FORD MOTOR CO.
  31. Install the thrust washer.
    Fig 26: Installing Thrust Washer
    G03276321Courtesy of FORD MOTOR CO.
  32. Install the countershaft reverse gear.
    1. Install the reverse synchronizer blocking ring.
    2. Install the two countershaft reverse gear needle bearings.
    3. Install the countershaft reverse gear.
      Fig 27: Installing Countershaft Reverse Gear
      G03276322Courtesy of FORD MOTOR CO.
  33. Measure the countershaft reverse gear end play.
    • Install the thrust washer and hold it against the shoulder on the countershaft while checking the end play.
    • Determine the correct thrust washer to obtain the correct end play. Remove the reverse gear and install the appropriate thrust washer. Reinstall the reverse gear.
      THRUST WASHER SELECT CHART

      Part Number Thickness mm (in)
      E8TZ-7C340-A 7.45 (0.293)
      E8TZ-7C340-B 7.65 (0.301)
      E8TZ-7C340-C 7.85 (0.309)
      E8TZ-7C340-D 7.35 (0.289)
      E8TZ-7C340-E 7.55 (0.297)
      E8TZ-7C340-F 7.75 (0.305)
      Fig 28: Measuring Countershaft Reverse Gear End Play
      G03276323Courtesy of FORD MOTOR CO.
  34. Install the output shaft spacer.
    Fig 29: Installing Output Shaft Spacer
    G03276324Courtesy of FORD MOTOR CO.
  35. Install the output shaft reverse gear.
    Fig 30: Installing Output Shaft Reverse Gear
    G03276325Courtesy of FORD MOTOR CO.
  36. Install the reverse idler gear.
    Fig 31: Installing Reverse Idler Gear
    G03276326Courtesy of FORD MOTOR CO.
    37. NOTE: Reverse idler shaft bolt must be installed within four minutes after applying the pipe sealant with Teflon®.
  37. Install the reverse idler shaft bolt.
    • Apply Pipe Sealant with Teflon® D8AZ-19554-A or equivalent meeting Ford specification WSK-M2G350-A2 to reverse idler shaft bolt threads.
      Fig 32: Installing Reverse Idler Shaft Bolt
      G03276327Courtesy of FORD MOTOR CO.
  38. Using the special tools, install the output shaft rear bearing.
    Fig 33: Installing Output Shaft Rear Bearing
    G03276328Courtesy of FORD MOTOR CO.
  39. Install the thrust washer and the countershaft rear bearing.
    Fig 34: Installing Thrust Washer And Countershaft Rear Bearing
    G03276329Courtesy of FORD MOTOR CO.
  40. Lock the transmission into first and third gear.
    Fig 35: Locking Transmission Into First And Third Gear
    G03276330Courtesy of FORD MOTOR CO.
  41. Using the Transmission Shaft Locknut Socket, install a new output shaft rear bearing lock nut.
    Fig 36: Installing Output Shaft Rear Bearing Lock Nut
    G03276331Courtesy of FORD MOTOR CO.
  42. Install a new countershaft lock nut.
    Fig 37: Installing Countershaft Lock Nut
    G03276332Courtesy of FORD MOTOR CO.
  43. Using the special tool, stake the output shaft rear bearing lock nut and the countershaft lock nut.
    Fig 38: Staking Output Shaft Rear Bearing Lock Nut
    G03276333Courtesy of FORD MOTOR CO.
  44. Install a new tone wheel, the lock bolt and the tone wheel snap ring.
  45. Install the extension housing.
    • Apply Gasket Maker F8AZ-19B508-AB or equivalent meeting Ford specifications WSKM2G348-A5 to the mating surfaces before installing.
      Fig 39: Installing Extension Housing
      G03276334Courtesy of FORD MOTOR CO.
  46. Using the special tool, install the extension housing seal.
    Fig 40: Installing Extension Housing Seal
    G03276335Courtesy of FORD MOTOR CO.
  47. Place the synchronizer sleeves in neutral.
    Fig 41: Placing Synchronizer Sleeves
    G03276336Courtesy of FORD MOTOR CO.
  48. Install the case cover with a new gasket.
    Fig 42: Installing Case Cover With Gasket
    G03276337Courtesy of FORD MOTOR CO.
  49. If equipped, install the damper.
    Fig 43: Installing Damper
    G03276338Courtesy of FORD MOTOR CO.
scientia non olet · About LEMON Manuals