NOTE: For 4x4 and F-Super Duty vehicles, start with Step 4.
Attach the transmission (7003) to the Bench Mounted Holding Fixture T57L-500-B. Place the transmission in a vertical position with the case (7005) pointing downward.
Section 07-03B: Transmission, Manual, Model S5-47 ZF | 1996 F-Series Vehicles Over 8500 lbs. GVW Workshop Manual |
| Description | Tool Number |
|---|---|
| Bench Mounted Holding Fixture | T57L-500-B |
| Companion Flange Holding Tool | T78P-4851-A |
| Locknut Socket | T87T-7025-AH |
| Jet Plug Remover | T77L-9533-B |
| Gear Pack Holding Fixture | T87T-7025-HH |
| Shift Rod Support | T87T-7025-JH |
NOTE: For 4x4 and F-Super Duty vehicles, start with Step 4.
Attach the transmission (7003) to the Bench Mounted Holding Fixture T57L-500-B. Place the transmission in a vertical position with the case (7005) pointing downward.
Attach Companion Flange Holding Tool T78P-4851-A to the transmission output flange.
CAUTION: Do not remove the hex nut or output flange at this time.
Loosen the spiral lock yoke nut that holds the output flange to the mainshaft with Locknut Socket T87T-7025-AH. Remove the flange holding tool after loosening the nut.
Remove 15 of the 17 8mm hex-head screws that hold the case and extension housing (7A039) together. Leave two screws at opposite sides of the extension housing installed.
Remove any power take-off equipment installed on the transmission.
CAUTION: Make sure that parts do not inadvertently fall into transmission when rotating.
Remove the eight 8mm hex bolts that attach the shift housing to the case. Remove the complete shift lever and shift lever housing as an assembly. Rotate transmission on holding fixture so that the case is pointing upward.
Remove the gear selector interlock sleeve (7K201) and shifter interlock spring (7234) which serves as a reverse gear interlock.
WARNING: DETENT SPRING PLUG IS UNDER SPRING PRESSURE. ALWAYS WEAR PROTECTIVE EYEGLASSES WHEN PERFORMING THIS PROCEDURE TO MAKE SURE THAT DETENT SPRING PLUG DOES NOT STRIKE EYES WHEN IT IS FORCED OUT BY SPRING PRESSURE.
NOTE: Discard removed detent spring plugs and replace with new detent spring plugs.
NOTE: The latest detent spring plugs are of a larger diameter than on older vehicles and will not work on older vehicles.
Puncture the center of the detent plug and screw in Jet Plug Remover T77L-9533-B and use its slide hammer to remove plug. Repeat this procedure for the other two detent spring plugs in the case.
Remove the springs that are now protruding from the holes.
Remove the reverse idler gear shaft bolts.
If required, remove the backup lamp switch (15520), located above and slightly forward of the transmission ID plate. Remove the sealing ring.
NOTE: The mainshaft is facing upward during this operation.
Use a suitable punch to remove the two dowel pins located in opposite corners of the mating surfaces of extension housing and case. Drive them out toward the rear of the transmission.
Remove the two remaining hex bolts from the extension housing.
CAUTION: The mating surfaces of case and extension housing are coated with an adhesive sealing agent. If it is difficult to separate case and extension housing because of this adhesive, carefully tap the front of the case with a soft hammer until the bond is loosened. Never use a prying device, such as a screwdriver or chisel, to force case and extension housing apart. This could damage the surfaces and cause leaks.
Carefully lift the case off the extension housing. It may be necessary to push the main gear shift rail inwards to prevent it from hanging up on the case as it is being removed. Use care to make sure that the main gear shift rail is not lifted off together with the case. Refer to Case in the Disassembly and Assembly of Subassemblies portion of this section for case disassembly and assembly procedures.
Remove the main gear shift rail and and shift finger.
Lift the reverse idler gear shaft (7140) out of the reverse idler gear, and remove the reverse idler gear and two reverse idler gear bearings from the case.
Remove the three selector plate bolts that retain the gear selector interlock sleeve to the extension housing.
With the transmission in a vertical position, use Endless Lifting Sling D87L-1000-A or equivalent to strap Gear Pack Holding Fixture T87T-7025-HH to the mainshaft and countershaft cluster gear (7113). Pass the sling over the shift rails.
Place the Shift Rod Support T87T-7025-JH over the ends of the shift rails.
Carefully rotate the transmission, together with the gear pack holding fixture, into a horizontal position with the holding fixture beneath the gear pack.
Remove the spiral lock output yoke lock nut from the mainshaft. Remove the flange from the mainshaft. If the mainshaft is difficult to remove, tap loose with a hammer.
Carefully pull the gearpack and shift rails and their holding fixtures forward to dislodge them from the extension housing. Place this assembly on a workbench.
If equipped, remove the spacer from the mainshaft.
Remove the sling from around the shift rails, gearpack, and holding fixture.
Turn the shift rails approximately 45 degrees to release them from the shift hubs. Lift the shift rails, 3-4 shifter forks and gear selector interlock sleeve, together with Shift Rod Support T87T-7025-JH, off the mainshaft.
Using the shift rod support tool as a base, set the shift rail assembly on a workbench with the shift rails in a vertical position. Remove the gear selector interlock plate.
Mark each gear shifter fork (7230), shift rail, and position in the holding fixture to make reassembly easier. Lift the shift rails from the support tool. Refer to Shift Lever Housing Assembly in the Disassembly and Assembly of Subassemblies portion of this section for disassembly procedures.
Lift the countershaft cluster gear off the bench stand. Separate the input shaft (7017) from the mainshaft. Lift the mainshaft from the stand. Refer to Mainshaft and to Bearing, Countershaft and to Input Shaft and Bearing in the Disassembly and Assembly of Subassemblies portion of this section.
Remove the rear cover from the holding fixture.