Transmission

NOTE: Any time the transmission (7003) is serviced check the following items:

• Confirm that the front bearing oil baffle is installed in the input shaft synchronizer cone recess.
• Visually inspect the front bearing oil baffle for tears or damage.
• The front bearing oil baffle is recessed 6mm (+1 -0mm) (0.24 inch [+0.04 -0 inch]) below the synchronizer cone edge.
• The front bearing oil baffle fits tight and cannot be moved by hand.
• The three lubrication holes in the input shaft (7017) are free of any obstruction.
• The oil channel (in the main case) to the bearing (7025) is free of any obstruction.
• The oil baffle (part of the shim pack) behind the outer race of the bearing is free of damage.
• The synchronizer body snap ring forward of the 3rd-4th synchronizer package on the mainshaft is in position.

1. Place the input shaft end over the input shaft pocket bearing on the input end of the mainshaft.

   
   
   
   
   

2. Place the mainshaft and input shaft on the Gear Pack Holding Fixture T87T-7025-HH. Place the countershaft cluster gear (7113) on the fixture and mesh the gears of the mainshaft and countershaft cluster gear.

   
   
   
   
   

3. Place the three shift rails and forks into the Shift Rod Support T87T-7025-JH in the position from which they were removed during disassembly.

4. Position the three shift rail assemblies together with the shift rod support tool and gear selector interlock plate so that the gear shifter forks (7230) engage in the correct sliding sleeves (part of mainshaft synchronizer (7124)).

   
   
   
   
   

5. Place the gear selector interlock plate on the three shift rails and engage it in the grooves of the gear selector interlock plate in the main shift rail.

   
   
   
   
   

6. Install spacer onto output shaft.

   
   
   
   
   

7. Secure the extension housing (7A039) into the Bench Mounted Holding Fixture T57L-500-B.

8. Position Endless Lifting Sling D87L-1000-A or equivalent around the shift rails, the holding fixture and the mainshaft and countershaft cluster gear. Position the gear pack into the extension housing and push the mainshaft and countershaft cluster gear and rails forward until the output shaft rear bearing (7R205) and output shaft bearing (7065) seat in their outer races in the extension housing and the shift rails slide into their retaining holes in the extension housing.

   
   
   
   
   

9. Rotate the gear pack and extension housing upwards 90 degrees so it is in a vertical position with the input shaft pointing upwards.

   
   
   
   
   

10. If equipped, slide the output flange onto the end of the mainshaft until it seats against its stop. Screw the spiral lock output yoke lock nut onto the mainshaft until it is finger-tight.

    
    
    
    
    

11. Remove the Shift Rod Support T87T-7025-JH.

    
    
    
    
    

12. Remove the strap and remove the gear pack holding fixture from the mainshaft and countershaft cluster gear.

    
    
    
    
    

13. Attach the three capscrews that secure the shift interlock to the rear transmission housing. Tighten them to 10 Nm (7 lb-ft). Be sure that the interlock moves freely after tightening the screws.

    
    
    
    
    

14. Engage the teeth of the reverse idler gear with the reverse gear. Slide the reverse idler gear shaft (7140) downward through the reverse idler gear bearings and into the extension housing. Align the lower of the two threaded holes in the reverse idler gear shaft with the bore in the extension housing. Place a sealing ring on the reverse idler shaft bolt and attach through the bore in the case (7005) into the reverse idler gear shaft. Tighten the screw finger-tight.

    
    
    
    
    

15. Insert the main shift rail with shift finger fork into its bore in the extension housing.

    
    
    
    
    

16. If the magnet was removed during disassembly, insert it in the recess in the extension housing.

    
    
    
    
    

17.  CAUTION: The tapered roller bearing preload should be adjusted if either the case or extension housing, countershaft cluster gear, mainshaft, input shaft, or a bearing has been replaced. If the tapered roller bearings on the mainshaft,input shaft, or countershaft cluster gear have to be adjusted, do not apply Gasket Maker E2AZ-19562-B or equivalent meeting Ford specification WSK-M2G348-A50.

     CAUTION: Do not use a silicone sealing compound.

    NOTE: Do not wait longer than ten minutes to tighten all 17 bolts, due to the rapid curing time of the sealant.

    If the tapered roller bearings do not have to be adjusted, thinly coat the sealing surface of the extension housing with Gasket Maker E2AZ-19562-B or equivalent meeting Ford specification WSK-M2G348-A50.

    
    
    
    
    

18.  CAUTION: Make sure that the shift rail detents do not obstruct entry of the shift rails.

    If removed, push the three shift rail detents back into their holes in the case.

    
    
    
    
    

19.  CAUTION: Be careful that the input shaft does not damage the input shaft seal and extension housing seal. Also be careful that the oil baffle is not bent when the case is positioned over the input shaft.

    Carefully place the case over the mainshaft and countershaft cluster gear and shift rails until it rests on its mating surface on the extension housing. It may be necessary to push the 5th-reverse shift rail inward to clear the inner surfaces of the case.

    
    
    
    
    

20. Drive in the two dowels that align the extension housing and the case. Next, insert two hex screws and tighten them finger-tight.

    
    
    
    
    

21. NOTE: If it is not necessary to adjust the mainshaft/input shaft preload, install all of the hex screws that attach case to extension housing and tighten to 23 Nm (17 lb-ft).

    Screw two additional hex screws into the bores of extension housing near the mainshaft and countershaft cluster gear finger-tight.

22.  CAUTION: The tapered roller bearing preload should be adjusted if either the case to extension housing, countershaft cluster gear, mainshaft, input shaft or a bearing has been replaced. Refer to Adjustments in this section.

    NOTE: The rear case reverse idler shaft bolt was installed finger-tight earlier.

    Fit sealing ring to the remaining reverse idler shaft shift rod bolt. Install the screw into the bore in the case and tighten both reverse idler shaft bolts to 22 Nm (16 lb-ft).

    
    
    
    
    

23. Rotate the transmission so the input shaft is pointing down.

24. On 4x2 transmissions (except F-Super Duty), remove the hex nut that secures the output flange to the mainshaft, then remove the flange from the mainshaft. Position the oil seal (7052) on Output Seal Replacer T87T-7025-LH and position the oil seal and tool in the opening in the extension housing. Apply a little liquid soap around the circumference to minimize friction. Using a soft hammer, gently tap the Rear Seal Replacer T87T-7025-BH until it seats in the opening.

    
    
    
    
    

25. On 4x4 and F-Super Duty transmissions, use Output Seal Replacer T87T-7025-LH and Remover Tube T77J-7025-B to install the oil seal. Gently tap on tube with a soft hammer until tool seats against its stop.

26.  CAUTION: Do not reuse the output yoke lock nut after any servicing of the transmission. Always replace it with a new one.

    On 4x2 transmissions (except F-Super Duty), reinstall the output flange on the mainshaft. Install Companion Flange Holder T78P-4851-A. Install a new spiral lock output yoke lock nut onto the mainshaft using Locknut Socket T87T-7025-AH. Tighten the output yoke lock nut to 270 Nm (200 lb-ft).

    
    
    
    
    

27. If required, install new PTO cover and gasket over the opening in the case using the original attaching screws which have self-sealing threads and tighten to 38 Nm (28 lb-ft).

    
    
    
    
    

28.  CAUTION: The procedure must be followed exactly to make sure that the interlock function operates properly.

    NOTE: Make sure that the interlock plate and shifter interlock spring (7234) do not drop into the case.

    Position the 5th-reverse gear interlock plate into its installed position as shown in the illustration following Step 30. Place the gasket over the mating surface of shift control housing in the case.

    Make sure that the stop plate moves freely and that the gasket does not interfere with it. The interlock plate must be in a position which is lower than the gasket so that the plate may move freely.

29. Unloaded length of shifter interlock spring is 35.5mm (1.398 inch) minimum.

30. Place the shifter interlock spring above the nose in the interlock plate and move both parts into their installed positions.

    
    
    
    
    

31.  CAUTION: Do not force the shift lever to shift into reverse. Damage to the interlock components could occur.

    Install the shift lever housing. Make sure gasket is positioned correctly.

    
    
    
    
    

32. Check the functioning of the interlock:

    1. Temporarily install the shift lever. The nose on the shift lever located just above the ball must point toward the interlock plate. Install spring washers and tighten screws to 22 Nm (16 lb-ft).
    2. The shift lever cannot be shifted between fifth and reverse if the interlock was properly installed.
    3. Once proper installation of the interlock is confirmed, remove shift lever.
       
       
       
       

33. A compression spring is installed into each of the three detent bolts. The positions are shown in the illustration. Before installing the springs, check that their unloaded length is 44.1mm (1.736 inch).

    
    
    
    
    

34.  CAUTION: Do not strike detent spring plug in center as such an action can cause the detent spring plug to cave in which will result in leakage.

    Vehicles have revised detent spring plugs on the housing. New detent spring plugs have a 14mm diameter versus the old 10mm diameter. Now detent spring plugs should be installed using a 14mm punch. There is no longer a need to measure the depth of the detent spring plug when installing it due to a positive stop in the housing to which the detent spring plug will be driven.

    
    
    
    
    

35. If removed, install the backup lamp switch (15520) with a new sealing ring into its mounting boss on the side of the transmission near the ID plate. Tighten the switch to 20 Nm (15 lb-ft).