Transmission Disassembly: Disassembly

1. Drain transmission, if not previously done. Remove top case cover (shift control housing). If extension housing seal is to be replaced, use Seal Remover SST 307-048 (T47P-77248-A), or equivalent, to remove extension housing seal. Remove extension housing.
2. Slide 1st-2nd and 3rd-4th synchronizer sleeves forward to lock transmission in 1st and 3rd gears. See Fig 1. Ensure staked areas securing output shaft and countershaft lock nuts are fully released (if applicable) or thread damage will occur. Remove and discard countershaft lock nut. Remove countershaft bearing and rear bearing thrust washer. Using Mainshaft Lock Nut Wrench (SST 49 UN01 011), or equivalent, remove and discard output shaft rear bearing lock nut.
3. Remove reverse idler gear shaft fixing bolt from right rear side of transmission case. See Fig 2. Remove reverse idler gear assembly by grasping and pulling rearward. Using Puller Bearing Set (SST49 0839 425C), or equivalent, remove output shaft rear bearing. See Fig 3. Remove output shaft reverse gear and bushing. Remove spacer or sleeve from output shaft.
4. Using brass drift and hammer, drive reverse gear from output shaft. Remove output shaft sleeve. See Fig 4. Remove countershaft reverse gear with 2 needle bearings and reverse synchronizer ring.
5. Remove thrust washer and split washer from countershaft. Remove 5th and reverse shift rod attaching bolt. Remove the following parts as an assembly; 5th-Reverse synchronizer hub and sleeve assembly (countershaft), 5th-Reverse shift fork and rod. Do not separate steel ball and spring (removed from shift fork groove) unless necessary.
6. Remove 5th gear synchronizer ring, 5th-Reverse counter lever lock plate bolt, inner circlip and counter lever assembly from transmission case. Do not remove Torx nut retaining counter lever pin at this time. Remove countershaft 5th gear with needle bearing.
7. Remove output shaft 5th gear using bearing collet (for 3 1/2" bearing), gear removal collet assembly and Remover/Replacer Tube (308-024) with Drive Screw (308-092). Remove 5th gear sleeve and Woodruff key or lock ball. Remove center and front bearing cover bolts.
8. To remove front bearing cover, thread 2 bolts (M8 X 1.25 - 40 mm or longer) into front bearing cover bolt locations at 3 and 9 o'clock positions (slave cylinder bolt holes). Alternately tighten bolts lifting front bearing cover away from transmission case. Do not remove plastic scoop ring from input shaft at this time.
9. Remove fluid passage (oil trough) retaining bolt from side of case. See Fig 5. Remove fluid passage. See Fig 6. Pull input shaft forward and remove input shaft bearing. Pull output shaft rearward.
10. Pull input shaft forward and separate it from output shaft assembly. Incline output shaft upward and lift from transmission case. Remove input shaft from transmission case.
11. Remove countershaft front and center bearings by moving countershaft forward and rearward. Pull countershaft rearward to permit clearance for bearing puller behind countershaft front bearing. Remove countershaft front bearing. Remove countershaft through top of transmission case.

Fig 1: Locking Transmission Into 1st & 3rd Gear

Courtesy of FORD MOTOR CO.

Fig 2: Removing Reverse Idler Gear Fixing Bolt

Courtesy of FORD MOTOR CO.

Fig 3: Removing Output Shaft Rear Bearing

Courtesy of FORD MOTOR CO.

Fig 4: Exploded View Of Rear Housing Components

Courtesy of FORD MOTOR CO.

Fig 5: Exploded View Of Transmission Main Case Components

Courtesy of FORD MOTOR CO.

Fig 6: Removing Fluid Passage (Oil Trough)

Courtesy of FORD MOTOR CO.