Disassembly
DISASSEMBLY1. Clamp output end of mainshaft firmly in a suitable soft jawed vise.
2. Remove 4th synchronizer ring from 3rd/4th synchronizer assembly.
3. Place bearing collets tool No. T87T-7025-FH or equivalent on either side of mainshaft front bearing.
4. Position puller tube, tool No. T77J-7025-B or equivalent in collets, then pass collet retaining collet retaining ring tool No. T75L-7025-G or equivalent over puller and into collets so they clamp firmly to bearing.
Installing Bearing Collets:
5. Pull bearing from mainshaft.
Removing 3rd/4th Gear Sleeve:
6. Remove 3rd/4th gear sliding sleeve from mainshaft. Place a cloth around synchronizer assembly to catch compression springs, pressure pieces and balls that will be released when sliding sleeves are removed.
7. Remove 3rd/4th synchronizer body to mainshaft retaining ring, the place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and let it rest on mainshaft 1st gear.
Installing Collet Retaining Ring:
8. Place two collets halves, tool No. T87T-7025-OH or equivalent on 3rd/4th synchronizer body and slide collet retaining ring over collet halves to hold them in place on synchronizer body.
9. Place shaft protector tool No.D8OL-625-4 or equivalent on end of mainshaft.
Removing Synchronizer Body:
10. Place the 3 jawed puller, tool No. D8OL-1013-A or equivalent on assembled collet halves and retaining ring, then pull synchronizer body from mainshaft.
11. Remove synchronizer ring from mainshaft 3rd gear, then the 3rd gear from mainshaft.
12. Remove 3rd gear caged needle roller bearings from mainshaft, then lift 1st/2nd gear sliding sleeve fully upwards.
13. Position collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft end, then allow to rest on 1st gear.
14. Position two collet halves tool No. T87T-7025-OH or equivalent, as to allow them to seat in groove in 1st/2nd sliding sleeve.
15. Pass retaining ring from below over two halves and secure them to sliding sleeve.
16. Position shaft protector D80L-625-4 or equivalent on end of mainshaft, then remove 1st/2nd sliding sleeve, 2nd gear thrust washer and 3rd gear bearing inner race from mainshaft, using a suitable puller.
17. On 4x4 and F-Super Duty models, remove snap ring and tapered roller bearing.
Removing Mainshaft Rear Tapered Roller Bearing:
18. On all models, place a suitable bearing gripper on mainshaft tapered roller bearing ensuring gripper is attached to bearing shoulder and bearing cage.
19. Remove rear tapered roller bearing from mainshaft, using a suitable puller on bearing gripper.
20. Remove 5th gear from mainshaft, then the 5th gear caged needle roller bearings from mainshaft.
21. Remove synchronizer ring from 5th reverse synchronizer, then the 5th/reverse synchronizer body to mainshaft snap ring.
22. Remove 5th/reverse sliding sleeve. Position a cloth around 5th/reverse synchronizer body to catch springs, pressure pieces and balls that will release when sliding sleeve clears 5th/reverse synchronizer body.
23. Place collet retaining ring tool No. T87T-7025-OH or equivalent over mainshaft and allow it to rest on 1st gear..
24. Position collet halves tool No. T87T-7025-NH or equivalent so as to allow ridge rests between synchronizer body and synchronizer ring.
25. Slide retaining ring upwards around collets to secure them in position.
26. Remove 5th/reverse synchronizer body from mainshaft, using a suitable 3 jawed puller.
27. Remove synchronizer ring from reverse gear, then the reverse gear from mainshaft.
28. Remove reverse gear caged needle bearings from mainshaft.
Removing 1st Gear:
29. Remove mainshaft from vise, then position mainshaft in a suitable press and press 1st gear and 1st/2nd synchronizer body from mainshaft. Ensure mainshaft is properly supported to prevent impact of mainshaft.
30. An alternate method to the previous step, is to invert mainshaft, then secure at output end. Remove gear using a suitable puller.
31. Remove 1st gear caged needle roller bearings from mainshaft.