Section 480 (Manual Transmission): Disassembly: Transmission

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.

Fig 1: Identifying Special Tool

G03276210

Courtesy of FORD MOTOR CO.

WARNING: Wear protective eyewear whenever using compressed air.

Clean the transmission exterior with solvent and dry with compressed air.

WARNING: Wear protective eyewear whenever using compressed air.

Clean all parts removed with solvent and dry with compressed air.
Set the transmission on a work bench.
Remove the case cover.
1. Remove the case cover bolts.
2. Remove the case cover.
  
  Fig 2: Removing Case Cover
  Courtesy of FORD MOTOR CO.
Using the special tool, remove the extension housing seal.

Fig 3: Removing Extension Housing Seal
Courtesy of FORD MOTOR CO.
If equipped, remove the damper.

Fig 4: Removing Damper
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Remove the eight bolts and the extension housing.

Fig 5: Removing Extension Housing
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Slide the first/second and third/fourth synchronizer sleeves forward to lock the transmission into first and third gears.

Fig 6: Locking Transmission Into First & Third Gears
Courtesy of FORD MOTOR CO.
Remove the tone wheel snap ring, the lock bolt, then remove and discard the tone wheel.
Using the Transmission Shaft Locknut Socket, remove and discard the output shaft rear bearing lock nut.

Fig 7: Removing Output Shaft Rear Bearing Lock Nut
Courtesy of FORD MOTOR CO.
Remove and discard the countershaft lock nut.

Fig 8: Removing Countershaft Lock Nut
Courtesy of FORD MOTOR CO.
Remove the countershaft rear bearing and the countershaft rear bearing thrust washer.

Fig 9: Removing Countershaft Rear Bearing And Countershaft Rear Bearing Thrust Washer
Courtesy of FORD MOTOR CO.
Remove the reverse idler shaft bolt.

Fig 10: Removing Reverse Idler Shaft Bolt
Courtesy of FORD MOTOR CO.
Remove the reverse idler gear and bushing.

Fig 11: Removing Reverse Idler Gear And Bushing
Courtesy of FORD MOTOR CO.
Using the special tools, remove the output shaft rear bearing.

Fig 12: Removing Output Shaft Rear Bearing
Courtesy of FORD MOTOR CO.
Remove the output shaft reverse gear.

Fig 13: Removing Output Shaft Reverse Gear
Courtesy of FORD MOTOR CO.
Remove the spacer.

Fig 14: Removing Spacer
Courtesy of FORD MOTOR CO.
Remove the countershaft reverse gear, the two countershaft reverse gear needle bearings, and the reverse synchronizer blocking ring.

Fig 15: Removing Countershaft Reverse Gear, Needle Bearings & Blocking Ring
Courtesy of FORD MOTOR CO.
Remove the thrust washer.

Fig 16: Removing Thrust Washer
Courtesy of FORD MOTOR CO.
Remove the countershaft split washer.

Fig 17: Removing Countershaft Split Washer
Courtesy of FORD MOTOR CO.
Remove the fifth/reverse gear shift rail bolt.

Fig 18: Removing Fifth/Reverse Gear Shift Rail Bolt
Courtesy of FORD MOTOR CO.
Remove the fifth/reverse synchronizer, the gear shifter fork, and the reverse gear shift rail as an assembly.

Fig 19: Removing Fifth/Reverse Synchronizer, Gear Shifter Fork & Shift Rail Assembly
Courtesy of FORD MOTOR CO.
Remove the countershaft fifth gear synchronizer blocking ring.

Fig 20: Removing Countershaft Fifth Gear Synchronizer Blocking Ring
Courtesy of FORD MOTOR CO.
Remove the fifth/reverse shift lever bolt and the nut, then remove the plate.

Fig 21: Removing Fifth/Reverse Shift Lever Bolt And Nut
Courtesy of FORD MOTOR CO.
Remove the fifth and reverse shift lever.
- Slide the fifth/reverse shift lever and shaft assembly from the case.
  
  Fig 22: Sliding Fifth/Reverse Shift Lever And Shaft Assembly
  Courtesy of FORD MOTOR CO.
Remove the countershaft fifth gear.

Fig 23: Removing Countershaft Fifth Gear
Courtesy of FORD MOTOR CO.
Remove the countershaft fifth gear split bearing and the race.

Fig 24: Removing Countershaft Fifth Gear Split Bearing And Race
Courtesy of FORD MOTOR CO.
Remove the locking ball.
Remove the output shaft fifth gear.

Fig 25: Removing Output Shaft Fifth Gear
Courtesy of FORD MOTOR CO.
Remove the rear bearing retainer.
1. Remove the retainer bolts.
2. Remove the bearing retainer.
  
  Fig 26: Removing Rear Bearing Retainer
  Courtesy of FORD MOTOR CO.
Remove the clutch slave cylinder. For additional information, refer to CLUTCH CONTROLS .
Remove the bolts.

Fig 27: Removing Bolts
Courtesy of FORD MOTOR CO.
Remove the main drive gear bearing retainer.
1. Install the Front Cover Remover into the clutch slave cylinder bolt locations.
  - Alternately tighten the bolts until the bearing retainer can be removed by hand.
2. Remove the main drive gear bearing retainer.
  
  Fig 28: Removing Main Drive Gear Bearing Retainer
  Courtesy of FORD MOTOR CO.
Remove the fluid baffle, the input bearing shim and the countershaft bearing shim.

Fig 29: Removing Fluid Baffle, Input Bearing Shim And Countershaft Bearing Shim
Courtesy of FORD MOTOR CO.
Remove the front oil cooler tube bolt.

Fig 30: Removing Front Oil Cooler Tube Bolt
Courtesy of FORD MOTOR CO.
Remove the oil cooler tube.

Fig 31: Removing Oil Cooler Tube
Courtesy of FORD MOTOR CO.
Remove the input shaft front bearing race.

Fig 32: Removing Input Shaft Front Bearing Race
Courtesy of FORD MOTOR CO.
Remove the output shaft center bearing race.

Fig 33: Removing Output Shaft Center Bearing Race
Courtesy of FORD MOTOR CO.
Separate the input shaft from the output shaft.

Fig 34: Separating Input Shaft From Output Shaft
Courtesy of FORD MOTOR CO.
Remove the output shaft.

Fig 35: Removing Output Shaft
Courtesy of FORD MOTOR CO.
Remove the input shaft and bearing.

Fig 36: Removing Input Shaft And Bearing
Courtesy of FORD MOTOR CO.
Remove the countershaft cluster gear.

Fig 37: Removing Countershaft Cluster Gear
Courtesy of FORD MOTOR CO.
Inspect the countershaft for wear or damage. Install a new countershaft as necessary.

Fig 38: Inspecting Countershaft For Wear Or Damage
Courtesy of FORD MOTOR CO.