2014 Mustang Workshop Manual

SECTION 308-03B: Manual Transaxle/Transmission — TR6060	2014 Mustang Workshop Manual
ASSEMBLY	Procedure revision date: 01/07/2013

Transmission

Special Tool(s)
	Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent
	Gauge, Clutch Housing 308-021 (T75L-4201-A)
	Handle 205-153 (T80T-4000-W)
	Holding Fixture, Transmission 307-003 (T57L-500-B)
	Installer, Transmission Extension Housing Bushing 308-254 (T96T-77110-A2 )
	Installer, Halfshaft 204-161 (T97P-1175-A)
	Installer, Input Shaft Oil Seal 308-220 (T94P-7025-AH)
	Remover/Installer, Bearing Tube 308-024 (T75L-7025-B)

Material
Item	Specification
MERCON® V Automatic Transmission Fluid XT-5-QM (or XT-5-QMC) (US); CXT-5-LM12 (Canada)	MERCON® V
Threadlock and Sealer TA-25	WSK-M2G351-A5
Thread Sealant with PTFE TA-24	WSK-M2G350-A2

Transmission Case and Shift Components — Disassembled View

Item	Part Number	Description
1	7W425	Shift rail bushing
2	7A082	Roll pin
3	7241	Reverse shift rail lever
4	7A082	Snap ring
5	7W425	Shift rail bushing
6	7241	5th/6th outer shift rail lever
7	7241	5th/6th outer shift lever pad
8	7241	5th/6th inner shift rail lever
9	7W425	Shift rail bushing
10	7L082	5th/6th shift fork pad
11	7241	Washer
12	7230	5th/6th shift fork
13	7241	Reverse shift rail
14	7A082	Roll pin
15	7L082	Reverse shift fork pad
16	7241	Shift rail collar
17	7230	Reverse shift fork
18	7241	Washer
19	7W425	Shift rail bushing
20	7L267	1st/2nd, 3rd/4th shift rail
21	7L082	3rd/4th shift fork pad
22	7230	3rd/4th shift fork
23	7A082	Roll pins
24	7814	Selector pin
25	7K201	Interlock plate
26	7L082	1st/2nd shift fork pad
27	7230	1st/2nd shift fork
28	—	Shift gate
29	7A082	Roll pins
30	7C453	Shift detent cover
31	—	Shift detent cover bolt (4 required)
32	—	Shift detent cover gasket
33	—	Reverse shift rail,
34	—	Shift guide plate bolt (2 required)
35	7F476	Shift guide plate
36	7A508	Clutch slave cylinder
37	6392	Clutch housing
38	7234	Shift detent plug
39	7234	Shift detent spring
40	7234	Shift detent
41	7127	Top shift rail bearing
42	7052	Input shaft seal
43	—	Oil pump pickup tube
44	—	Transmission main case-to-clutch housing gasket
45	7005	Transmission main case
46	7A082	Snap ring
47	7025	Output shaft bearing cup
48	—	Extension housing gasket
49	7A010	Case plug
50	7A443	OSS sensor bolt
51	7H103	OSS sensor
52	7025	Output shaft bearing
53	7A082	Output shaft bearing snap ring
54	7052	Extension housing seal
55	7089	Output flange
56	7F273	Internal o-ring
57	7119	Thrust washer
58	7K440	Output flange nut
59	—	Reverse lockout solenoid bolt
60	7374	Reverse lockout solenoid
61	7A039	Extension housing
62	7L027	Magnet

Transmission Gear Assemblies — Disassembled View

Item	Part Number	Description
1	7L172	Shim
2	7025	Input shaft bearing/race
3	7017	Input shaft
4	7025	Cylindrical roller bearing
5	7025	Axial thrust bearing
6	7025	Axial thrust washer
7	7A082	Snap ring
8	—	4th gear synchronizer ring assembly
9	7124	3rd/4th synchronizer assembly
10	7107	3rd synchronizer ring assembly
11	7117	Spacer
12	7M037	3rd gear needle bearing
13	7B340	3rd gear
14	7061	Output shaft
15	7M037	2nd gear needle bearing
16	7102	2nd gear
17	7117	Spacer
18	7107B	2nd gear synchronizer ring assembly
19	7124A	1st/2nd synchronizer assembly
20	7107A	1st gear synchronizer ring assembly
21	7A082A	Split ring
22	7A082A	Retainer
23	7025	1st gear needle bearing
24	7100	1st gear
25	7025	Output shaft rear bearing/race
26	7L047	6th driven gear
27	7K316	5th driven gear
28	7A082	Retainer
29	7A082	Split ring
30	—	Synchronizer cone (part of 7107)
31	7124B	Reverse synchronizer assembly
32	7A082	Snap ring
33	7107C	Reverse gear synchronizer ring assembly
34	7C238	Reverse gear
35	7025	Reverse gear needle bearing
36	7A385	Thrust washer
37	7A082	Snap ring
38	7A082	Spacer
39	7025	Rear output shaft bearing
40	7A082	Spacer
41	7A082	Snap ring
42	7E172	Check ball
43	7H150	OSS sensor tone wheel
44	7A082	Snap ring
45	7L172	Shim
46	7025	Countershaft front bearing/race
47	7113	Countershaft
48	7025	Countershaft rear bearing/race
49	7119	Thrust washer
50	7117	Spacer
51	7146	6th gear
52	7025	6th gear needle bearing
53	7107	6th gear synchronizer ring assembly
54	7124	5th/6th synchronizer assembly
55	7107	5th gear synchronizer ring assembly
56	7117	Spacer
57	7A082	Snap ring
58	7144	5th gear
59	7025	5th gear needle bearing
60	7025	Thrust washer
61	7A082	Snap ring
62	—	Reverse driver gear
63	7A082	Snap ring
64	7C211	Reverse idler shroud bracket bolt
65	7723	Reverse idler shaft bracket
66	7141	Reverse idler gear
67	7025	Reverse idler gear needle bearing
68	7140	Reverse idler gear shaft

Lubricate all components with clean transmission fluid during assembly.

Attach the transmission clutch housing to the Transmission Holding Fixture.

NOTE: If a new front input shaft bearing or front countershaft bearing was installed, install the new bearing cups.
Install the input shaft bearing cup and the countershaft bearing cup. Do not install the shims at this time.

Install the input shaft, the cylindrical roller bearing, the axial thrust bearing and the 4th gear synchronizer ring assembly.
- Align the synchronizer ring tabs with the gear slots.

Install the output shaft onto the input shaft.
- Align the synchronizer ring tabs with the synchronizer hub slots.

NOTICE: Make sure the countershaft seats into the oil pump drive or damage to the oil pump or transmission case can occur.
Align the oil pump drive with the countershaft and install the countershaft.
- Lift the output shaft upward, tilt the countershaft and install.

Install the transmission main case-to-clutch housing gasket and the transmission main case.

Install the 11 transmission main case-to-clutch housing bolts.
- Tighten the bolts in a star pattern to 48 Nm (35 lb-ft).

NOTICE: The input shaft/output shaft end play must be measured with a gasket installed between the clutch housing and the transmission main case or incorrect end play will occur.
NOTE: Rotate the input shaft/output shaft to seat the bearings.
Using the Dial Indicator Gauge with Holding Fixture and the Clutch Housing Gauge, measure the input shaft/output shaft end play by applying an upward load on the input shaft. Record the measurement.

NOTICE: The countershaft shaft end play must be measured with a gasket installed between the clutch housing and the transmission main case or incorrect end play will occur.
NOTE: Rotate the countershaft to seat the bearings.
Using the Dial Indicator Gauge with Holding Fixture and the Clutch Housing Gauge, measure the countershaft gear end play by pulling upward on the countershaft. Record the measurement.

Remove the 11 transmission main case-to-clutch housing bolts, the transmission main case and the gasket.

Remove the countershaft and output shaft.

Remove the input shaft assembly.

Remove the input shaft bearing cup and the countershaft bearing cup.

Using the Input Shaft Oil Seal Installer with Handle, install the new input shaft seal.

Using the recorded end play measurements, select and install the appropriate shims to achieve the correct end play. Input shaft, output shaft and countershaft endplay specification is 0.0127-0.0889 mm (0.0005-0.0035 in).

Install the input shaft bearing cup and the countershaft bearing cup.
- Lubricate the bearing cups with petroleum jelly.

Install the input shaft, the cylindrical roller bearing, the axial thrust bearing and the 4th gear synchronizer ring assembly.
- Align the synchronizer ring tabs with the gear slots.

Assemble the shift rail assembly to the output shaft, then install the output shaft and shift rail as an assembly.
- Align the 4th gear synchronizer ring tabs with the 4th gear synchronizer hub slots.

NOTICE: Make sure the countershaft seats into the oil pump drive or damage to the oil pump or transmission case can occur.
Align the oil pump drive with the countershaft and install the countershaft.
- Lift the output shaft upward, tilt the countershaft and install.

Install the 6th gear spacer and thrust washer.

Install the 5th/6th and reverse shift rail assembly and align the slots of the shift levers with the shift interlock plate.

Install the shift detent, the shift detent spring and the shift detent plug.
- Apply thread sealant to the threads of the shift detent plug.
- Tighten to 40 Nm (30 lb-ft).

Install the oil pump pickup tube.

Install the new transmission main case-to-clutch housing gasket.

Install the transmission main case and the front offset lever.
- Make sure the transmission is in NEUTRAL to keep the 3rd/4th gear shift rail from engaging.

Install the 11 transmission main case-to-clutch housing bolts.
- Tighten the bolts in a star pattern to 48 Nm (35 lb-ft).

Apply threadlock and sealer to the threads of the shift lever guide bolts, then install the bolts.
- Pull up on the 5th/6th shift rail to align the slot of the interlock plate with the guide bolt hole.
- Tighten to 27 Nm (20 lb-ft).

Install a new front offset lever roll pin.
- Install the roll pin flush with the offset lever.

Install the 6th gear needle bearing and 6th gear.
- Apply petroleum jelly to the needle bearing.

Install the 6th gear synchronizer ring assembly.
- Align the synchronizer ring tabs with the gear slots.

Using the Bearing Tube Remover/Installer and a soft faced hammer, install the 5th/6th gear synchronizer hub.
- Align the synchronizer ring tabs with the synchronizer hub slots.

NOTE: Slide the synchronizer sleeve down while installing the pressure pieces.
Install the 5th/6th gear shift fork, the 5th/6th gear synchronizer sleeve and the 3 pressure pieces as an assembly.

Install the new 5th/6th shift fork snap ring.

Install a new snap ring on the countershaft.

Install the 5th gear synchronizer ring assembly.
- Align the synchronizer ring tabs with the synchronizer hub slots.

Install the spacer and the 5th drive gear needle bearing.
- Apply petroleum jelly to the needle bearing.

Install the following components:
1. The 5th drive gear.
  - Align the synchronizer ring tabs with the gear slots.
1. The 5th drive gear thrust washer.
1. A new 5th drive gear snap ring.

Using the Bearing Tube Remover/Installer and a soft faced hammer, install the reverse drive gear.

Install a new reverse drive gear snap ring.

Using the Bearing Tube Remover/Installer and a soft faced hammer, position the 5th driven gear onto the second set of the output shaft splines.

NOTE: Align the gear teeth of the 5th driven gear with the gear teeth of the 5th drive gear on the countershaft.
Using the Bearing Tube Remover/Installer, the Halfshaft Installer and the Transmission Extension Housing Bushing Installer, install the 5th driven gear in 2 stages:
- Stage 1: Using the Bearing Tube Remover/Installer and the Halfshaft Installer, press the 5th driven gear down to align with the countershaft 5th drive gear.
- Stage 2: Using the Bearing Tube Remover/Installer, the Halfshaft Installer and the Transmission Extension Housing Bushing Installer, press the 5th driven gear down to seat on the 6th driven gear.

Install the split ring and retainer.

Using the Bearing Tube Remover/Installer and a soft faced hammer, install the reverse gear synchronizer hub.
- Align the synchronizer ring tabs with the synchronizer hub slots.

NOTE: Slide the synchronizer sleeve down while installing the pressure pieces.
Install the reverse shift fork, the reverse synchronizer sleeve and the 3 pressure pieces as an assembly.

Install a new reverse shift fork snap ring.

Install a new reverse gear synchronizer snap ring.

Install the reverse gear synchronizer rings assembly.
- Align the synchronizer ring tabs with the synchronizer hub slots.

Install the reverse gear needle bearing.
- Apply petroleum jelly to the needle bearing.

Install the reverse gear.
- Align the synchronizer ring tabs with the gear slots.

Install the reverse gear thrust washer.

Install a new reverse gear snap ring.

Install the lower spacer, the rear output shaft roller bearing and the upper spacer.

Install a new rear output shaft roller bearing snap ring.

Position the check ball on the output shaft. Install the OSS sensor tone wheel.

Install a new OSS sensor tone wheel snap ring.

Install the reverse shift rail, then install a new roll pin.
- Install the roll pin until it is flush with the lever.

Install the bearing spacer and the race.

Install the new extension housing gasket.

NOTE: Install the transmission identification tag in the location noted during removal.
NOTE: Apply thread sealant to the threads of the 2 top extension housing bolts.
Install the extension housing and the 8 extension housing bolts.
- Tighten to 48 Nm (35 lb-ft).

Install the new shift detent cover gasket.

Install the shift detent cover and the 4 shift detent cover bolts.
- Tighten to 20 Nm (177 lb-in).

Install the output shaft flange and a new internal o-ring. Install the output shaft flange nut as follows:
- Using the old flange nut, tighten to 135 Nm (100 lb-ft).
- Remove the nut and discard.
- Install a new flange nut and tighten to 142 Nm (105 lb-ft).

Install the clutch slave cylinder and the 2 clutch slave cylinder bolts.
- Tighten to 12 Nm (106 lb-in).