Remove the synchronizer ring from the 3rd-4th synchronizer (7124).
Section 07-03B: Transmission, Manual, Model S5-47 ZF | 1996 F-Series Vehicles Over 8500 lbs. GVW Workshop Manual |
| Description | Tool Number |
|---|---|
| Bearing Collets | T87T-7025-FH |
| Remover Tube | T77J-7025-B |
| Bearing Collet Sleeve | T75L-7025-G |
| Inner Pinion Bearing Cone Replacer | T85T-4621-AH |
Disassembly
NOTE: Use brass pads or equivalent in vice jaws to prevent damage to mainshaft.
Clamp the output end of the mainshaft firmly in a vise.
Remove the synchronizer ring from the 3rd-4th synchronizer (7124).
Place the Bearing Collets T87T-7025-FH or equivalent on either side of the input shaft pocket bearing. Position the Remover Tube T77J-7025-B in the collets. Pass the Bearing Collet Sleeve T75L-7025-G over the Remover Tube T77J-7025-B and into the collets so they clamp firmly to the input shaft pocket bearing. Pull the input shaft pocket bearing from the mainshaft.
CAUTION: Place a cloth around the synchronizer to catch the compression springs and pressure pieces that will be released when the sliding sleeves are removed.
Remove the 3rd-4th gear sliding sleeve (part of synchronizer) from the mainshaft.
Remove the snap ring part of small parts repair kit that retains the 3rd-4th synchronizer body to the mainshaft.
Place Bearing Pulling Attachment D79L-4621-A or equivalent over the mainshaft and let it rest on the mainshaft.
Place the Shaft Protector D80L-625-4 or equivalent on the end of the mainshaft. Place the Push-Puller Set D80L-927-A or equivalent on the assembled collet halves and retaining ring and pull the synchronizer body from the mainshaft.
Remove the synchronizer ring (part of synchronizer) from the 3rd gear of mainshaft.
Remove the 3rd gear from the mainshaft.
Remove the 3rd gear bearings from the mainshaft.
Lift the 1st-2nd gear sliding sleeve (part of synchronizer) up as far as it will slide.
Position Bearing Pulling Attachment D79L-4621-A or equivalent over the mainshaft and let it rest on the first gear (1GR) (7100).
Position the two collet halves of Bearing Pulling Attachment D79L-4621-A or equivalent so they seat in the groove in the 1st-2nd sliding sleeve (part of synchronizer).
CAUTION: Position a cloth around the 1st-2nd synchronizer to catch the springs and pressure pieces that will be released when the sliding sleeve (part of synchronizer) clears the 1st-2nd synchronizer.
Position Shaft Protector D80L-625-4 or equivalent on the end of the mainshaft. Position the Push-Puller Set D80L-927-A or equivalent on the Collet Retaining Ring and pull the 1st-2nd sliding sleeve (part of synchronizer), 2nd gear, thrust washer (7119), and input bearing spacer from the mainshaft.
| Item | Part Number | Description |
|---|---|---|
| 1 | D80L-927-A | Push-Puller Set |
| 2 | D80L-625-4 | Shaft Protector |
| 3 | 7173 | Input Bearing Spacer |
| 4 | 7119 | Thrust Washer |
| 5 | 7101 | Second Gear |
| 6 | — | 1st-2nd Sliding Sleeve (Part of 7124) |
Remove the snap ring (part of small parts repair kit) retaining the 1st-2nd synchronizer body to the mainshaft.
NOTE: Use brass pads or equivalent to prevent damage.
Reposition the mainshaft in the vise so that the output end of the mainshaft is now facing up.
CAUTION: Failure to use a bearing gripper will destroy the output shaft rear bearing (7R205).
NOTE: On 4x4 versions and F-Super Duty versions, a snap ring (part of small parts repair kit) retaining the taper roller bearing inner race must be removed.
Position a bearing gripper such as Bearing Pulling Attachment D79L-4621-A or equivalent on the output shaft rear bearing. The gripper used must pull the output shaft rear bearing by the shoulder of the tapered rollers, not from the bearing cage.
Position Push-Puller Set D80L-927-A or equivalent on the bearing gripper and pull the output shaft rear bearing from the mainshaft.
Remove the 5th gear from the mainshaft.
Remove the 5th gear bearing from the mainshaft.
Remove the synchronizer ring (part of synchronizer) from the 5th-reverse synchronizer.
Remove the snap ring (part of small parts repair kit) retaining the 5th-reverse synchronizer body to the mainshaft.
CAUTION: Position a cloth around the 5th-reverse synchronizer to catch the springs and pressure pieces that will be released when the sliding sleeve clears the 5th-reverse synchronizer.
Remove the 5th-reverse sliding sleeve (part of synchronizer).
Place Bearing Pulling Attachment D79L-4621-A or equivalent over the mainshaft and let it rest on the 1st gear.
Position Push-Puller Set D80L-927-A or equivalent on the Bearing Pulling Attachment D79L-4621-A or equivalent and pull the 5th-reverse synchronizer body from the mainshaft.
Remove the synchronizer ring (part of synchronizer) from the reverse gear.
Remove the reverse gear from the mainshaft.
Remove the reverse gear bearing from the mainshaft.
Remove the mainshaft from the vise.
CAUTION: Make sure mainshaft is properly supported.
Position the mainshaft in a press as shown in the illustration and press the first gear and the 1st-2nd synchronizer from the mainshaft.
An alternate method is to clamp the mainshaft at the output end. Position the jaws of Push-Puller Set D80L-927-A or equivalent and Bearing Puller Attachment D79L-4621-A or equivalent on the first gear and pull the first gear and the 1st-2nd synchronizer from the mainshaft.
Remove the 1st speed gear bearing from the mainshaft.
Assembly
NOTE: Use brass pads or equivalent to prevent damage.
Clamp the input end of the mainshaft in a vise.
Place the reverse gear bearing on the mainshaft.
CAUTION: Before installing original synchronizer, check for excessive wear. Refer to wear check of synchronizer under Synchronizers in the Cleaning and Inspection portion of this section.
Place the reverse gear on the mainshaft over the reverse gear bearing. The clutching teeth on the reverse gear must face upwards.
Position the reverse gear synchronizer ring (part of synchronizer) on the taper of the reverse gear.
CAUTION: Do not heat synchronizer body for more than 15 minutes.
Heat the 5th-reverse synchronizer body with a Precision Metal Gear/Bearing Heater 164-R3900, Heat Gun 107-R0300 or equivalent to 160°C (320°F).
Position the synchronizer body on the mainshaft so that the side with the deeper hub faces down and the short lugs on the synchronizing ring (part of synchronizer) engage in the shallow gaps in the synchronizer body. Push or lightly tap the synchronizer body down until it stops.
CAUTION: Make sure snap ring (part of small parts repair kit) is free of burrs before checking clearance.
Install the snap ring (part of small parts repair kit) on the mainshaft next to the 5th-reverse synchronizer body. The clearance between the snap ring (part of small parts repair kit) and the synchronizer body should not be more than 0.1mm (0.004 inch) with zero clearance preferable.
Check the reverse gear end play. End play must be between 0.15-0.35mm (0.00591-0.01378 inch).
There are two grooves on the 5th-reverse sliding sleeve (part of synchronizer). With the two grooves facing up (toward output end of mainshaft), position the sliding sleeve over the synchronizer body (both part of synchronizer). In three positions on the sliding sleeve, three teeth have been cut away. Align these three areas with the three shallow gaps in the synchronizer body and the three lugs on the synchronizer ring (part of synchronizer). Slide the sliding sleeve down until it rests over the clutching teeth of reverse gear.
CAUTION: If the original springs (part of countershaft pilot bearing) are not being replaced, inspect them before reuse. Refer to Synchronizer Compression Spring Tension Check in the Cleaning and Inspection portion of this section for procedure.
Insert three compression springs with each pressure piece in the recesses of the synchronizer body (all part of synchronizer).
NOTE: The short lugs on the synchronizer ring should be located over the shallow gaps in the 5th-reverse synchronizer body.
Place the 5th gear synchronizer ring on the synchronizer body (both part of synchronizer).
Push the 5th gear synchronizer ring (part of synchronizer) downwards while pulling the sliding sleeve (part of synchronizer) into the center position.
Place 5th gear bearing on the mainshaft.
Install the 5th gear on the mainshaft over the 5th gear bearing.
CAUTION: Do not heat the output shaft rear bearing for more than 15 minutes.
CAUTION: If necessary to drive the output shaft rear bearing on, drive against the inner race only. Do not drive against the bearing cone.
Heat the inner race of the output shaft rear bearing to 160°C (320°F) with Rotunda Precision Metal Gear/Bearing Heater 164-R3900 or equivalent. Place it on the mainshaft and drive it on if necessary until it seats against its stop on the mainshaft.
NOTE: On 4x4 and F-Super Duty versions, fit an additional retaining ring (part of small parts repair kit) in the annular groove adjacent to the inner race. It must have an end play of 0.0-0.1mm (0.0-0.004 inch). 0mm (0.0 inch) should be aimed for.
Check the end play of the 5th gear. End play must be 0.15-0.35mm (0.006-0.014 inch).
NOTE: Use brass pads or equivalent to prevent damage.
Turn the mainshaft over and clamp it at the output end.
Place the first gear bearing on mainshaft.
Place the first gear over the first gear bearing. The clutching teeth on first gear must face upward.
Place the synchronizer ring (part of synchronizer) on the taper of the first gear.
CAUTION: Do not heat the synchronizer body for more than 15 minutes.
Heat the 1st-2nd synchronizer body to 160°C (320°F) with Rotunda Precision Metal Gear/Bearing Heater 164-R3900 or equivalent. Position the synchronizer body on the mainshaft so that the short lugs on the synchronizing ring (part of synchronizer) engage in the shallow gaps in the synchronizer body. Lightly tap the synchronizer body down until it stops against the synchronizer ring (part of synchronizer). When proper installation is made, the word ENGINE will be visible on the synchronizer body.
Install a new snap ring on the mainshaft next to the 1st-2nd synchronizer body (part of small parts repair kit). Clearance between the snap ring and the synchronizer body should not be more than 0.1mm (0.004 inch).
Check the end play of the first gear. It must be between 0.15 and 0.35mm (0.006 and 0.014 inch).
Position the sliding sleeve over the synchronizer body with its tapered collar facing down (toward the output end of the mainshaft). In three positions on the sliding sleeve, three teeth have been cut away. Align these three areas with the three shallow gaps in the synchronizer body and the three lugs on the synchronizer ring. Slide the sliding sleeve down until it rests against the first gear.
CAUTION: If the original springs are not being replaced, inspect them before reuse. Refer to Synchronizer Compression Spring Tension Check in the Cleaning and Inspection portion of this section for procedure.
Insert three compression springs with each pressure piece (part of small parts repair kit) in the recesses of the synchronizer.
NOTE: The short lugs on the synchronizer ring should be located over the gaps in the 1st-2nd synchronizer body.
Place the 2nd gear synchronizer ring (part of synchronizer) on the 1st-2nd synchronizer body.
Push the synchronizer ring downwards while pulling the sliding sleeve into the center position.
Place the second speed gear bearing on the mainshaft.
Place the 2nd gear over the second speed gear bearing on the mainshaft. The taper of the 2nd gear must face down on the mainshaft.
CAUTION: Do not heat the thrust washer for more than 15 minutes.
Heat the thrust washer to 160°C (320°F) with Rotunda Precision Metal Gear/Bearing Heater 164-R3900 or equivalent.
Position the thrust washer on the mainshaft and tap it down until it seats against its stop on the mainshaft. If necessary, gently tap the thrust washer to fully seat it.
CAUTION: Do not heat the input bearing spacer (7173) for more than 15 minutes.
Heat the 3rd-speed bearing spacer to 160°C (320°F) with Rotunda Precision Metal Gear/Bearing Heater 164-R3900 or equivalent.
Position the 3rd gear bearing spacer on the mainshaft and tap it down until it seats against its stop on the mainshaft. If necessary, gently tap the 3rd speed bearing spacer to fully seat it.
Check the end play of the 2nd gear. It must be between 0.15-0.45mm (0.006-0.017 inch).
After the 3rd-speed bearing spacer has fully cooled, place the 3rd speed gear bearing over it.
Place the 3rd gear over the 3rd-speed gear bearing on the mainshaft. The taper of the 3rd gear must face up.
Place the 3rd gear synchronizer ring (part of synchronizer) on the taper of the 3rd gear.
CAUTION: Do not heat the synchronizer for more than 15 minutes.
Heat the 3rd-4th synchronizer body with Rotunda Precision Metal Gear/Bearing Heater 164-R3900 or equivalent to a maximum 160°C (320°F). Position the synchronizer body on the mainshaft so that the short lugs on the synchronizer ring (part of synchronizer) engage in the shallow gaps in the synchronizer body. Lightly tap the synchronizer body down until it stops against the synchronizer ring (part of synchronizer). The recess in the synchronizer body must face upwards.
Install a new snap ring on the mainshaft next to the 3rd-4th synchronizer body (part of small parts repair kit). Clearance between the snap ring and the synchronizer body should not be more than 0.1mm (0.004 inch).
Check the end play of the 3rd gear. It must be between 0.15 and 0.35mm (0.00591 and 0.01378 inch).
Position the sliding sleeve over the synchronizer body (both part of synchronizer) with the smaller of the two grooves facing down. In three positions on the sliding sleeve, three teeth have been cut away. Align these three areas with the three shallow gaps in the synchronizer body and the three lugs on the synchronizer ring (part of synchronizer). Slide the sliding sleeve (part of synchronizer) down until it rests against the 3rd gear.
CAUTION: If the original springs are not being replaced, inspect them before reuse. Refer to Synchronizer Compression Spring Tension Check in the Cleaning and Inspection portion of this section for procedure.
Insert three compression springs with each pressure piece (part of small parts repair kit) in the recesses of the synchronizer body.
NOTE: The short lugs on the synchronizer ring (part of synchronizer) should be located over the shallow gaps in the 3rd-4th synchronizer body.
Place the 4th gear synchronizer ring (part of synchronizer) on the synchronizer body.
Push the synchronizer ring downwards while pulling the sliding sleeve (both part of synchronizer) into the center position.
CAUTION: Do not heat the input shaft pocket bearing for more than 15 minutes.
CAUTION: If necessary to drive the input shaft pocket bearing on, drive against the inner race only. Do not drive against the bearing cone.
Heat the inner race of the input shaft pocket bearing to 160°C (320°F) with Rotunda Precision Metal Gear/Bearing Heater 164-R3900 or equivalent. Position it on the mainshaft and drive it on if necessary until it seats against its stop on the mainshaft.
An alternate method is to press the input shaft pocket bearing on using Inner Pinion Bearing Cone Replacer T85T-4621-AH.
