Section 07-03A: Transmission, Manual, M5OD
1996 F-Series and Bronco (under 8500 lbs. GVW) with 4.9L and 5.0L Engines Workshop Manual
DISASSEMBLY

Transmission

SPECIAL SERVICE TOOL(S) REQUIRED
DescriptionTool Number
Mainshaft Locknut WrenchT88T-7025-AR
Remover/Replacer TubeT75L-7025-B
TOD Forcing ScrewT84T-7025-B
Bearing PullerT77J-7025-H
Bearing Collet SleeveT75L-7025-G
Collet HalfT88T-7061-A

  1. Remove transmission (7003) from vehicle as outlined in this section. Secure to an appropriate holding fixture.

    M5OD Transmission Assembly

  1. Using a 12mm wrench, remove ten retaining bolts. Remove case cover.

  1. Remove shift control selector lever and housing and gearshift lever boot if necessary.

  1. Using a 12mm wrench, remove 10 retaining bolts. Remove case cover.

  1. Remove and discard extension housing seal (4x2 vehicles only).

  1. Remove extension housing (7A039) from case, refer to Extension Housing Removal in this section.

  1. Remove countershaft rear bearing and thrust washer.

  1. Using Mainshaft Locknut Wrench T88T-7025-AR and Remover/Replacer Tube T75L-7025-B, remove and discard lock nut from output and fifth gear driveshaft.

  1. Using a 17mm wrench, remove holding bolt from reverse idler gear shaft (7140). Remove reverse idler gear assembly by grasping and pulling rearward.

    ItemPart NumberDescription
    17061Output Shaft
    27214Bolt
    37N037Thrust Washer with Tang
    47141Reverse Idler Gear and Bushing
    57156Retaining Ring
    67140Reverse Idler Gear Shaft

  1.  CAUTION: Make sure tools are properly positioned so as not to damage parts being removed.

    Removeoutput shaft bearing (7065) from output shaft using Remover/Replacer Tube T75L-7025-B, TOD Forcing Screw T84T-7025-B and Bearing Puller T77J-7025-H.

    ItemPart NumberDescription
    1T75L-7025-BRemover/Replacer Tube
    2T77J-7025-HBearing Puller
    37R205Output Shaft Rear Bearing
    4T84T-7025-BTod Forcing Screw

  1. Using a brass drift and hammer, drive reverse gear from output shaft.

  1. Remove sleeve from output shaft.

  1. Remove countershaft reverse gear with two reverse idler gear bearings and reverse synchronizer blocking ring (7107).

    Transmission, Rear Housing

    ItemPart NumberDescription
    17B364Lock Nut
    27R205Output Shaft Rear Bearing
    37142Output Shaft Reverse Gear
    47072Spacer or Sleeve
    57141Reverse Idler Gear and Bushing
    67085Bearing Retainer
    77K179Reverse Idler Gear Holding Bolt
    899796-0612Bolt
    97214Fifth and Reverse Shift Rod Bolt
    1099611-2000Ball
    117173Input Bearing Spacer
    127112Fifth Gear
    137R130Needle Bearing, Fifth Gear
    147142Fifth Gear, Countershaft
    157107Synchronizer Blocking Ring
    167124Synchronizer
    177107Synchronizer Blocking Ring
    187R482Synchronizer Split Washer
    197C340Thrust Washer
    207N040Countershaft Reverse Gear
    217L324Thrust Washer
    227N170Lock Nut
    237D283Countershaft Rear Bearing
    247N270Needle Bearing
    257289Lockball (Steel) Shift Rail
    2699796-0612Bolt
    277289Shift Fork (5th and Reverse)

  1. Remove thrust washer and split washer from countershaft.

  1. Using a 12mm wrench, remove holding bolt fromreverse gear shift rail (7240).

  1. Remove the fifth/reverse synchronizer and fifth/reverse gear shifter fork (7230) as an assembly without separating the steel ball and shifter interlock spring (7234) (removed from shift fork groove) unless necessary.

  1. Remove fifth gear synchronizer blocking ring.

  1. NOTE: Do not remove the Torx® nut retaining the shift lever connecting pin at this time.

    Remove the lockplate retaining bolt and inner circlip. Remove fifth and reverse shift lever from transmission case.

  1. Remove fifth gear (counter) with needle bearing.

  1. NOTE: For reference during assembly, observe that the longer of the two collars on fifth gear faces forward.

    Remove fifth gear from output shaft using Bearing Collet Sleeve for 3.5-inch Bearing Collets T75L-7025-G, Remover/Replacer Tube T85T-7025-A, TOD Forcing Screw T84T-7025-B and Collet Half T88T-7061-A.

  1. Remove fifth gear spacer or sleeve and (positioning) ball.

  1. Remove front and rear bearing retainers. Refer to procedures in this section.

  1. Using a 10mm socket, remove oil trough retaining bolt and oil trough from upper transmission case.

    ItemPart NumberDescription
    17052Center Bearing Outer Race
    27111Countershaft
    37D283Countershaft Rear Bearing
    47A174Oil Bypass Tube
    599796-0620Bolt
    699796-0825Bolt
    77050Main Drive Gear Bearing Retainer
    87065Output Shaft Bearing
    97025Bearing
    107017Input Shaft
    117061Output and Fifth Gear Driveshaft

  1. Pull input shaft (7017) forward and removebearing (7025). Pull input shaft rearward.

  1. Pull input shaft forward and separate it from output shaft. Incline output shaft upward and lift it from case (7005).

  1. Remove input shaft from case.

  1. Remove countershaft through upper opening of case.