Section 07-03B: Transmission, Manual, Model S5-47 ZF | 1996 F-Series Vehicles Over 8500 lbs. GVW Workshop Manual |
| 1st | 2nd | 3rd | 4th | 5th | Reverse | |
|---|---|---|---|---|---|---|
| Close Ratio (Diesel) | 5.08 | 2.60 | 1.53 | 1.0 | 0.77 | 4.66 |
| Wide Ratio (Gasoline Diesel) | 5.72 | 2.94 | 1.61 | 1.0 | 0.76 | 5.24 |
| Temperature | ||
|---|---|---|
| C | F | |
| Taper Roller Bearing Inner Race | 160 | 320 |
| Synchronizer Bodies | 160 | 320 |
| Thrust Washer | 160 | 320 |
| Needle Bearing Inner Race | 160 | 320 |
| Bearing Outer Race in Cover | 160 | 320 |
| Ball Bearing Sleeve in Cover | 160 | 320 |
| Description | mm | Inches |
|---|---|---|
| Countershaft (Preload) | 0.02-0.11 | 0.00079-0.00434 |
| Input Shaft and Mainshaft (Preload) | 0.02-0.11 | 0.00079-0.00434 |
| Mainshaft Reverse Gear | 0.15-0.35 | 0.00591-0.01378 |
| Mainshaft 1st Gear | 0.15-0.35 | 0.00591-0.01378 |
| Mainshaft 2nd Gear | 0.15-0.45 | 0.00591-0.0177 |
| Mainshaft 3rd Gear | 0.15-0.35 | 0.00591-0.01378 |
| Mainshaft 5th Gear | 0.15-0.35 | 0.00591-0.01378 |
| Mainshaft Synchronizer Body Retention Rings | 0-0.1 | 0-0.00394 |
| Length | Outer Diameter | Wire Diameter | |
|---|---|---|---|
| Detent Springs | 44.1mm (1.736 In.) Min. | 7.880mm (0.310 In.) | 1.250mm (0.049 In.) |
| Reverse Gear Stop Plate Spring | 35.5mm (1.398 In.) Min. | 9.040mm (0.356 In.) | 1.000mm (0.039 In.) |
| Synchronizer Spring | 14.8mm (0.583 In.) Min. | 5.960mm (0.235 In.) | 0.950mm (0.037 In.) |
| Description | Liters | U.S. Qts. | Imp. Qts. |
|---|---|---|---|
| Motorcraft MERCON® Multi-Purpose Automatic Transmission Fluid XT-2-QDX or -DDX or MERCON® Equivalent | 3.2 | 3.4 | 2.8 |
| 7.3L Diesel Motorcraft Synthetic MERCON® Multi-Purpose Automatic Transmission Fluid E6AZ-19582-B or MERCON® Equivalent Meeting Ford Specification ESR-M2C163-A2 | 3.2 | 3.4 | 2.8 |
| Description | Nm | Lb-Ft | Lb-In |
|---|---|---|---|
| Transmission Case Plug (Straight Threads with Sealing Ring) | 60 | 44 | — |
| Extension Adapter to Main Case | 23-33 | 17-24 | — |
| End Yoke to Mainshaft | 270 | 200 | — |
| Shift Tower Cover to Main Case | 23 | 17 | — |
| PTO Cover Plate | 38 | 28 | — |
| Idler Shaft Retention | 22 | 16 | — |
| Shift Rail Plate | 10 | 7 | — |
| Shift Cover to Tower Cover | 10 | 7 | — |
| Backup Lamp Switch | 20 | 15 | — |
| Upper Shift Lever | 22-33 | 16-24 | — |
| Transmission to Engine Bolts | 53-72 | 39-53 | — |
| Diesel Engine Charge Exhaust Pipe to Transmission Housing | 54-68 | 40-50 | — |
| Shift Rail Interlock | 10 | 7 | — |
| Case to Extension Housing | 23 | 17 | — |
| Case Plugs to Case | 60 | 44 | — |
| Upper Gusset (F-250 4x4) | 58-77 | 43-57 | — |
| Crossmember to Frame (F-250) | 58-77 | 43-57 | — |
| Transmission Support Plate to Crossmember (F-250) | 81-109 | 60-81 | — |
| Transmission Support Plate to Transmission | 64-71 | 47-52 | — |
| Crossmember to Frame (F-350) | 43-57 | 32-42 | — |
| Gusset (F-350) | 43-57 | 32-42 | — |
| Crossmember to Transmission (F-350) | 81-109 | 60-81 | — |
| Gearshift Lever Boot to Floor Plate | 5-9 | — | 44-80 |
| Release Bearing Guide Tube Bolts | 24 | 18 | — |
| Transmission Support Crossmember | 60-80 | 45-60 | — |
| Insulator and Retainer Nut | 68-94 | 50-70 | — |
| Transmission to Engine Block | 54-68 | 40-50 | — |
| Rear Support Bracket | 60-80 | 45-60 | — |