Transmission

Tools Required:

• Bench Mounted Holding Fixture T57L-500-B
• Pinion Bearing Cone Replacer T57L-4621-B
• Remover Tube T77J-7025-B
• Front Hub Remover/Replacer T81P-1104-C1
• Cluster Gear Bearing Installer T83P-7025-AH
• Bearing Pulling Attachment D84L-1123-A
• Dial Indicator with Bracketry TOOL-4201-C

Disassembly

1. Mount transmission in Bench Mounted Holding Fixture T57L-500-B.
   
   
   
   

2. Using a 3/8-inch drive ratchet and extension, remove drain plug located on lower RH side of transmission case.
   
   
   
   

3. Using a 13mm socket, position shift lever in NEUTRAL position and remove turret cover retaining bolts.
   
   
   
   

4. Using a suitable pry bar, break turret cover-to-extension housing seal by prying carefully between housing and cover. Remove turret cover.
   
   
   
   

    CAUTION: Do not attempt to remove the offset lever while the extension housing is bolted in place. A lug, located on the bottom of the offset lever, meshes with the detent plate preventing enough rearward movement of the offset lever to allow removal.

5. Using a suitable pin punch and hammer, remove roll pin retaining offset lever to shifter shaft. Remove damper sleeve.
   
   
   
   

6. Using a 15mm socket, remove extension housing retaining bolts.
   
   
   
   

7. Using a suitable pry bar, break extension housing-to-case seal by prying carefully between housing and case.
   
   
   
   

8. Remove extension housing and offset lever as an assembly by sliding rearward away from case.
   
   
   
   

9. Remove offset lever, roll pin, detent spring and detent ball from extension housing detent plate.
   
   
   
   

10. Using a 10mm socket, remove shift cover retaining bolts.
    
    
    
    

11. Using a suitable pry bar, break cover-to-case seal by prying carefully between cover and case.
    
    
    
    

12. To remove shift cover, lift it slightly and slide to filler plug side of transmission. When shift mechanism clears groove in fifth/reverse shift lever, continue lifting cover.
    
    
    
    

13. Support fifth/reverse shift rail assembly with a block of wood and drive out roll pin from fifth gear shift fork with a suitable pin punch.
    
    
    
    

14. Using snap ring pliers, remove fifth gear synchronizer snap ring retainer, brake ring and synchronizer blocking ring from rear of countershaft.
    
    
    
    

15. Remove fifth gear, synchronizer and shift fork as an assembly.
    
    
    
    

16. Using long needlenose pliers, remove C-clip retaining fifth/reverse shift lever to lever pivot pin.
    
    
    
    

17. Remove fifth/reverse shift lever pivot pin with Torx® bit driver. Do not remove the fifth/reverse shift lever at this point.

18. Using a 22mm wrench, remove the backup lamp switch.
    
    
    
    

19. Rotate fifth/reverse shift rail clockwise to disengage ball stud from fifth/reverse shift lever. Pull fifth/reverse shift rail rearward slightly and rotate shift rail counterclockwise to align ball stud with slot in case and remove shift rail.
    
    
    
    

20. Press downward on speedometer gear retaining clip and slide gear off of output shaft. Remove retaining clip.
    
    
    
    

21. Using a 13mm socket, remove bearing retainer retaining bolts.
    
    
    
    

22. Using a suitable pry bar, break the bearing retainer-to-case seal by prying carefully between retainer and case. Remove bearing retainer.
    
    
    
    

23. Rotate input shaft until flat on 4th gear clutching teeth aligns with countershaft. With input shaft properly aligned, remove it from case. Be careful not to drop the 15 roller bearings, thrust bearing or race from rear of input shaft.
    
    
    
    

24. Remove fourth gear synchronizer blocking ring from the third/fourth synchronizer.
    
    
    
    

    NOTE: If the race sticks, it is probably misaligned in the case bore. To free the race, work the shaft back and forth in the case.

25. Remove output shaft bearing race from rear of case. To partially remove bearing race, pull rearward on output shaft until first gear stops against case.
    
    
    
    

26. Tilt output shaft assembly upward and lift out of case.
    
    
    
    

    NOTE: Observe location of shift lever, shift fork and inhibitor spring prior to removal. Also observe the rotation action of the reverse positioning spring during removal. This will be helpful during assembly.

27. Remove fifth/reverse shift lever, reverse shift fork and reverse positioning spring from case by grasping lever and lifting straight up as an assembly. If case replacement is necessary, remove reverse positioning spring anchor pin by removing the Tizz bushing from the anchor bolt head and then removing the anchor bolt.
    
    
    
    

28. Using a suitable pin punch and hammer, remove roll pin from reverse idler shaft.
    
    
    
    

29. Remove reverse idler shaft by sliding it out of back of case. Remove reverse idler gear and overtravel rubber stop from case.
    
    
    
    

30. Using a hammer and Locknut Staking Tool T77J-7025-F, flatten tabs on countershaft retainer at all four corners.
    
    
    
    

31. Remove four 13mm bolts from countershaft retainer.
    
    
    
    

32. Remove countershaft retainer and shim(s).
    
    
    
    

33. Remove rear countershaft bearing race from countershaft.

    NOTE: If the race sticks, it is probably misaligned in the case bore. To free the race, work the shaft back and forth in case.

    
    
    
    
    

34. Install Front Hub Remover/Replacer T81P-1104-C1 and Bearing Pulling Attachment D84L-1123-A or equivalent to the countershaft with the jaws behind the countershaft bearing, and remove bearing.
    
    
    
    

35. Move countershaft rearward through bearing bore. Tilt assembly upward and remove from case.
    
    
    
    

Assembly

1. Using a press, install front countershaft bearing onto countershaft using Pinion Bearing Cone Replacer T57L-4621-B.
   
   
   
   

2. Position countershaft in case.

    CAUTION: Failure to properly support the countershaft can result in permanent distortion of the case during bearing installation.

   
   
   
   
   

   NOTE: Support the countershaft using two pieces of 7mm (1/4 inch) bar stock.

3. Using a press and Cluster Gear Bearing Installer T83P-7025-AH and Remover Tube T77J-7025-B, install countershaft rear bearing to countershaft.
   
   
   
   

4. Install rear countershaft bearing race onto countershaft.
   
   
   
   

5. Install countershaft bearing retainer to transmission housing with four 13mm bolts.

   NOTE: This should be done initially without any shims installed. Tighten bolts to 15-27 Nm (11-20 lb-ft).

   
   
   
   
   

6. Measure end play using Dial Indicator with Bracketry TOOL-4201-C, or equivalent.

   Remove retainer and install necessary shim(s) between countershaft retainer and rear countershaft bearing race. Verify end play is within 0.0254-0.127mm (0.001-0.005 inch). After installing countershaft retainer, bend tabs on retainer over the four attaching bolts.
   
   
   
   

7. Position reverse idler gear in case with shift lever groove facing rear of case.

   Install reverse idler shaft and rubber overtravel stop. Install shaft from rear of case and position overtravel stop between gear and shaft support.
   
   
   
   

8. Using a 5mm (3/16-inch) pin punch, install reverse idler shaft roll pin.
   
   
   
   

9. If removed, apply Pipe Sealant with Teflon® D8AZ-19554-A (ESG-M4G194-A and ESR-M18P7-A) or equivalent to reverse positioning spring anchor pin threads. Install anchor pin and tighten to 8-15 Nm (6-11 lb-ft). Install Tizz bushing over anchor pin head by tapping lightly into position with hammer.

10. Align fifth/reverse shift lever, reverse shift fork and reverse positioning spring as shown.
    
    
    
    

11. Lower assembly into case and install looped end of reverse positioning spring onto anchor pin.
    
    
    
    

12. Position reverse idler gear into the NEUTRAL position and align reverse shift fork onto reverse idler gear. Once aligned, push downward on shift fork until fully engaged into reverse idler gear.

    NOTE: Observe reverse positioning spring rotation. Reverse positioning spring should rotate counterclockwise into its installed position.

    
    
    
    
    

13. Install output shaft assembly.
    
    
    
    

    NOTE: The following step is not required for Mustang Cobra.

14. Coat the 15 input shaft roller bearings, thrust bearing and race with Multi-Purpose Grease D0AZ-19584-AA (ESR-M1C159-A and ESB-M1C93-A) or equivalent. Install components in input shaft.
    
    
    
    

15. Align notches in synchronizer blocking ring with inserts in 3-4 synchronizer and install synchronizer blocking ring.
    
    
    
    

16. Install input shaft. Align flat on synchronizer teeth with countershaft before installing input shaft.

    NOTE: Ensure 3-4 synchronizer blocking ring is still in proper position.

    
    
    
    
    

17. Install bearing race in bearing retainer.

    NOTE: Do not install end play shims at this point.

    
    
    
    
    

18. Temporarily, install bearing retainer with narrow or smaller notch facing upward. Do not apply sealant to the retainer at this point.

19. Tighten retaining bolts to 15-27 Nm (11-20 lb-ft).
    
    
    
    

20. Install output shaft rear bearing race. If necessary, tap bearing race into position using a plastic tipped hammer.
    
    
    
    

21. Install fifth/reverse shift rail into transmission case by aligning ball stud with slot in case and aligning shift rail with reverse shift fork. Once ball stud enters case, rotate shift rail clockwise and push in shift rail until ball aligns with fifth/reverse shift lever. Rotate shift rail counterclockwise until ball stud fully engages shift lever.
    
    
    
    

22. Install fifth gear, synchronizer and shift fork as an assembly.
    
    
    
    

23. Install fifth gear synchronizer blocking ring, brake ring, retainer and snap ring.

    NOTE: Ensure tabs on retainer engage splines of countershaft.

    
    
    
    
    
    
    
    
    

    NOTE: Before installing the pivot pin, ensure the shift rail ball stud is fully engaged with the shift lever.

24. Apply Pipe Sealant with Teflon® D8AZ-19554-A (ESG-M4G194-A and ESR-M18P7-A) or equivalent to the pivot pin threads and install the fifth/reverse shift lever pivot pin.

    Tighten pivot pin to 34-47 Nm (25-35 lb-ft) using a T55 Torx® driver. Apply Pipe Sealant with Teflon® D8AZ-19554-A (ESG-M4G194-A and ESR-M18P7-A) or equivalent to the backup lamp switch and install using a 22mm socket. Tighten to 27-47 Nm (20-35 lb-ft).
    
    
    
    

25. Using needlenose pliers, install C-clip on shift lever pivot pin.
    
    
    
    

26. Install speedometer gear.

    NOTE: The tab on the retainer clip engages a hole in the output shaft.

    
    
    
    
    

     CAUTION: Do not apply silicone sealer to top of transmission case surface under any circumstances, as sealant could fall into transmission and affect operation.

27. Apply 3.2mm (1/8 inch) bead of Silicone Rubber D6AZ-19562-AA or BA (ESB-M4G92-A and ESE-M4G195-A) or equivalent to shift cover assembly.

    NOTE: Ensure all synchronizers are in the NEUTRAL position and that the shift forks in the cover are in the NEUTRAL position.

    Position cover to filler plug side of transmission and lower into position until shift forks engage synchronizers. Continue lowering cover and move into position to engage fifth/reverse shift lever.

28. Install shift cover retaining bolts. Tighten cover retaining bolts to 8-15 Nm (6-11 lb-ft).
    
    
    
    

29. Apply a 3.2mm (1/8 inch) bead of Silicone Rubber D6AZ-19562-AA or BA (ESB-M4G92-A and ESE-M4G195-A) or equivalent on the extension housing mating surface. Apply Silicone Rubber D6AZ-19562-AA or BA (ESB-M4G92-A and ESE-M4G195-A) or equivalent to the lubrication funnel and install funnel to extension housing.
    
    
    
    

30. Coat detent spring with petroleum jelly and install in offset lever. Lubricate detent plate and install detent ball in neutral position on plate. Position offset lever in extension housing with spring over detent ball.
    
    
    
    

31. Slide lever and extension housing into position as an assembly.

    NOTE: Make sure lubrication funnel engages into fifth gear synchronizer.

    
    
    
    
    

32. Press downward on offset lever to compress detent spring and push lever and housing into position.
    
    
    
    

33. Install extension housing retaining bolts. Tighten to 47-61 Nm (30-45 lb-ft).
    
    
    
    

34. Using a suitable pin punch, align the hole in shifter shaft with hole in offset lever and install roll pin.

    Install damper sleeve in offset lever.

    NOTE: Output shaft geartrain end play must be checked and adjusted at this point.

    
    
    
    
    

35. Check output shaft geartrain end play as follows:
    • Rotate transmission to the vertical position with extension housing facing up.
    • Mount Dial Indicator with Bracketry TOOL-4201-C or equivalent on the extension housing with the indicator stylus contacting the output shaft.
    • Rotate the input and output shafts. Zero the dial indicator.
    
    
    
    
    
    • Using a wood block, push upward on the input shaft and note the dial indicator reading.

    NOTE: A shim must be installed that is the thickness of the dial indicator reading. This will provide zero end play.

     CAUTION: Although zero end play is the ideal end play specification, a plus or minus .050mm (0.002 inch) is an acceptable tolerance. Do not overload the bearings with too thick a shim.

    
    
    
    
    

     CAUTION: Thickest shim must be installed closest to the front bearing cup.

36. Rotate transmission to the horizontal position and remove the front bearing retainer. Remove bearing race from retainer and install the necessary shim(s).
    
    
    
    

37. Apply a 3.2mm (1/8 inch) bead of Silicone Rubber D6AZ-19562-AA or BA (ESB-M4G92-A and ESE-M4G195-A) or equivalent to bearing retainer.
    
    
    
    

    Install bearing retainer with narrow or smaller notch facing upward, and tighten retaining bolts to 15-27 Nm (11-20 lb-ft). Check end play.

     CAUTION: The sealer must not cover the notch in the bearing retainer.

38. Apply a 3.2mm (1/8 inch) bead of Silicone Rubber D6AZ-19562-AA or BA (ESB-M4G92-A and ESE-M4G195-A) or equivalent on the turret cover.
    
    
    
    

39. Position turret cover on the extension housing and tighten the retaining bolts to 17-20 Nm (12-15 lb-ft).
    
    
    
    

40. Install and tighten drain plug to 17-29 Nm (12-22 lb-ft).