Position front flange of output shaft as illustrated. Use this flange as a reference point and dividing line during assembly and disassembly procedures.
Section 07-03A: Transmission, Manual, M5OD | 1996 F-Series and Bronco (under 8500 lbs. GVW) with 4.9L and 5.0L Engines Workshop Manual |
| Description | Tool Number |
|---|---|
| Pinion Bearing Cone Replacer | T53T-4621-B |
| Bearing Cone Replacer | T88T-7025-B |
| Axle Bearing/Seal Plate | T75L-1165-B |
| Remover/Replacer Tube | T75L-7025-B |
| Output Shaft Bearing Replacer | T83T-7025-B |
Disassembly
Position front flange of output shaft as illustrated. Use this flange as a reference point and dividing line during assembly and disassembly procedures.
Remove input shaft bushing, bearing outer snap ring, thrust bearing and third and fourth synchronizer spacer from front (short side of flange) of output shaft.
| Item | Part Number | Description |
|---|---|---|
| 1 | 7127 | Gear Bearing |
| 2 | 7101 | Third Gear |
| 3 | 7107 | Synchronizer Blocking Ring |
| 4 | 7124 | Synchronizer |
| 5 | 7N112 | Third and Fourth Synchronizer Spacer |
| 6 | 7C096 | Thrust Bearing |
| 7 | 7030 | Bearing Outer Snap Ring |
| 8 | 7120 | Bearing |
Position the front (short side of flange) of output shaft so that it faces upward. Lift off the following components as a unit:
CAUTION: Make sure flange does not contact or ride up onto press cradle. Improper positioning can result in component damage.
Position output shaft with rear end (long side of flange) facing upward. Position output shaft into press using Pinion Bearing Cone Replacer T53T-4621-B as a press plate contacting the lower part of second gear and Bearing Cone Replacer T88T-7025-B to protect the inner race rollers.
Press off the following components as a unit: mainshaft bearing roller, input bearing spacer, first gear (1GR), first and second speed gear bearing, first/second synchronizer, first/second synchronizer blocking rings, second gear and first and second speed gear bearing using Pinion Bearing Cone Replacer T53T-4621-B and Bearing Cone Replacer T88T-7025-B.
Assembly
NOTE: Make note of the differences between the third gear synchronizer blocking ring and the first, second and fourth gear synchronizer blocking rings. The third gear synchronizer blocking ring has three teeth out 120 degrees apart from each other. Directly adjacent to one side of the missing teeth, two teeth have been bridged together. This is to help eliminate any upshift "crunch" that may occur.
NOTE: During assembly, apply Motorcraft MERCON® Multi-Purpose Automatic Transmission Fluid XT-2QDX or -DDX or equivalent MERCON® to all rotating or sliding parts.
Position output shaft so that the rear end (long side of flange) faces upward. Install the following parts in the order listed:
NOTE: Make sure mainshaft bearing roller is still positioned in case (7005).
NOTE: When installing first/second synchronizer, make sure narrow width of sleeve faces second gear (front) side. Make sure reference marks face rear of transmission (7003); they reference installation position of synchronizer hub insert (7A044).
To install components onto output shaft, position components as shown. Press components into position using Pinion Bearing Cone Replacer T53T-4621-B and Axle Bearing/Seal Plate T75L-1165-B.
| Item | Part Number | Description |
|---|---|---|
| 1 | 7133 | First and Second Speed Gear Bearing |
| 2 | 7102 | Second Gear |
| 3 | 7107 | Synchronizer Blocking Ring |
| 4 | 7124 | Synchronizer |
| 5 | 7100 | First Gear |
| 6 | 7173 | Input Bearing Spacer |
| 7 | 7118 | Mainshaft Bearing Roller |
Press the center bearing onto the output shaft using the following tools:
Position the output shaft on a press cradle as shown in the following illustration. Using the sleeve and replacer tube as a press ram, seat the center bearing.
| Item | Part Number | Description |
|---|---|---|
| 1 | — | Press |
| 2 | 7C096 | Thrust Bearing |
| 3 | 7061 | Output Shaft |
| 4 | — | Bearing Plate |
| 5 | T83T-7025-B | Output Shaft Bearing Replacer |
| 6 | T75L-7025-B | Remover/Replacer Tube |
Position output shaft so that front (short side) of output shaft flange faces upward. Install the following parts in the order listed.
NOTE: Make note of the differences between the third gear synchronizer blocking ring and the first, second and fourth gear synchronizer blocking rings. The third gear synchronizer blocking ring has three teeth cut out 120 degrees apart from each other. Directly adjacent to one side of the missing teeth, two teeth have been bridged together. This is to help eliminate any upshift "crunch" that may occur.
NOTE: The front and rear sides of the clutch hub may appear to be similar. Be sure to install it with the longer flange side (with reference mark) facing rearwards.
Install third/fourth synchronizer as follows:
Install the third and fourth synchronizer spacer and bearing outer snap ring onto the output and fifth gear driveshaft.
With the original bearing outer snap ring installed, measure the clutch hub end play using a feeler gauge.
If necessary, adjust third/fourth clutch hub end play to 0.00-0.05mm (0.00-0.0019 inch) by selecting required bearing outer snap ring according to the chart.
| Part Number | Thickness |
|---|---|
| E8TZ-7030-A | 1.50mm (0.059 In.) |
| E8TZ-7030-B | 1.55mm (0.061 In.) |
| E8TZ-7030-C | 1.60mm (0.0629 In.) |
| E8TZ-7030-D | 1.65mm (0.0649 In.) |
| E8TZ-7030-E | 1.70mm (0.0669 In.) |
| E8TZ-7030-F | 1.75mm (0.0688 In.) |
| E8TZ-7030-G | 1.80mm (0.0708 In.) |
| E8TZ-7030-H | 1.85mm (0.0728 In.) |
| E8TZ-7030-J | 1.90mm (0.0748 In.) |
| E8TZ-7030-K | 1.95mm (0.0767 In.) |
After determining the correct bearing outer snap ring, install the needle bearing (with the rollers visible), bearing outer snap ring and pilot bearing.