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Special Tool(s)

Depth Micrometer 303-D026 (D80P-4201-A) or equivalent

Installer, Bearing Shaft Collar 308-031 (T75L-7025-K)

Installer, Bearing Shaft Collar 308-035 (T75L-7025-P)

Installer, Clutch Housing Oil Seal 308-057 (T77J-7025-G)

Installer, Transmission Extension Housing Oil Seal 308-002 (T61L-7657-A)

Remover/Installer, Bearing Tube 308-098 (T85T-7025-A)

Socket, Transmission Shaft Locknut 308-168 (T88T-7025-AR)

Spacer, Gear 308-174 (T88T-7025-G)

Staking Tool, Locknut 308-056 (T77J-7025-F)

Material

Item Specification

Gasket Maker TA-16

WSK-M2G348-A5

Silicone Gasket and Sealant TA-30

WSE-M4G323-A4

Thread Sealant with PTFE TA-24

WSK-M2G350-A2

of 132007 Ranger Workshop Manual

2/19/2010http://www.fordtechservice.dealerconnection.com/pubs/content/~WS7L/~MUS~LEN/19/S...

Item Part Number Description

1 7005 Main case

2 7L276 Funnels

3 — Dowels (part of 7A039)

4 7A174 Oil passage

5 7A039 Extension housing —Rear Wheel Drive (RWD)

6 7052 Oil seal

7 7A039 Extension housing —Four-Wheel Drive (4WD)

8 7052 Oil seal

9 7085 Retainer

10 7C277 Lock plate

11 7N428 Nut

12 7214 Reverse gear shift rail bolt

13 7564 Clutch housing cover

14 7050 Bearing retainer

15 7052 Oil seal

16 7046 Oil scoop ring

17 7040 Oil baffle

18 7A174 Oil passage

19 7C434 Spacer

20 7065 Countershaft front roller bearing

21 7113 Countershaft

22 7121 Countershaft roller bearing

23 7173 Sleeve

24 7R130 Countershaft cluster gear needle bearing

25 7158 Countershaft cluster gear needle bearing

26 7107 Synchronizer ring, 5th/reverse gear

27 7124 Synchronizer assembly, 5th/reverse gear

28 7107 Synchronizer ring, 5th/reverse gear

29 7R482 Thrust washer (2-piece)



Assembly

1. Install the countershaft cluster gear.

2. Position the input shaft.

3. NOTE: Verify the 4th gear synchronizer blocking ring is in place.

Install the output shaft.

4. Position the input shaft and output shaft together.

5. Install the countershaft front and rear roller bearings.

6. Install the output shaft rear bearing and input shaft bearing.

30 7C340 Thrust washer

31 7N040 Countershaft reverse gear (only serviced in 3-piece 7141 kit)

32 7N270 Countershaft reverse gear needle bearing

33 7N270 Countershaft reverse gear needle bearing

34 7L324 Thrust washer, countershaft

35 7C096 Countershaft rear roller bearing

36 7N170 Locknut, countershaft



7. NOTE: Install the rear bearing retainer with the arrow pointing to the top of the case.

Install the rear bearing retainer and the 6 rear bearing retainer bolts. � Tighten to 22 Nm (16 lb-ft).

8. NOTE: If any related parts (such as the output shaft and bearings) have been installed new, carry out the shim thickness selective procedure.

Using the Clutch Housing Oil Seal Installer, install the front cover oil seal.

9. Position the transmission with the clutch housing facing up.

10. Using the Depth Micrometer, measure the input shaft bearing race depth. � Record the reading on Line 2 of the Selective Shim Equation Chart.

11. Using the Depth Micrometer, measure the front bearing retainer depth. � Record the reading on Line 1 of the Selective Shim Equation Chart.

12. Calculate and select the correct output shaft shim. Refer to the Output Shaft Shim Selective Chart. Selective Shim Equation Chart

Step Measurement mm (in)



Output Shaft Shim Selective Chart

13. Using the Depth Micrometer, measure the countershaft bearing depth.

� Record the reading on Line 1 of the Countershaft Spacer Equation Chart.

14. Using the Depth Micrometer, measure the countershaft bearing retainer depth. � Record the reading on Line 2 of the Countershaft Spacer Equation Chart.

Line 1 (Dimension B)

Line 2 (Dimension A)

Line 3 (Subtract line 2 from line 1)

Total From Line 3 Part Number Thickness

2.75-2.85 mm (0.108-0.112 in) E8TZ-7029-C 2.7 mm

(0.106 in)

2.85-2.95 mm (0.112-0.116 in) E8TZ-7029-D 2.8 mm

(0.110 in)

2.95-3.05 mm (0.116-0.120 in) E8TZ-7029-E 2.9 mm

(0.114 in)

3.05-3.15 mm (0.120-0.124 in) E8TZ-7029-F 3.0 mm

(0.118 in)

3.15-3.25 mm (0.124-0.127 in) E8TZ-7029-G 3.1 mm

(0.122 in)

3.25-3.35 mm (0.127-0.131 in) E8TZ-7029-H 3.2 mm

(0.125 in)

3.35-3.45 mm (0.131-0.135 in) E8TZ-7029-J 3.3 mm

(0.129 in)

3.45-3.55 mm (0.135-0.139 in) E8TZ-7029-K 3.4 mm

(0.133 in)

3.55-3.65 mm (0.139-0.143 in) E8TZ-7029-L 3.5 mm

(0.137 in)

3.65-3.75 mm (0.143-0.147 in) E8TZ-7029-M 3.6 mm

(0.141 in)

3.75-3.85 mm (0.147-0.151 in) E8TZ-7029-N 3.7 mm

(0.145 in)

3.85-3.95 mm (0.151-0.155 in) E8TZ-7029-P 3.8 mm

(0.149 in)

3.95-4.05 mm (0.155-0.159 in) E8TZ-7029-R 3.9 mm

(0.153 in)

4.05-4.15 mm (0.159-0.163 in) E8TZ-7029-A 4.0 mm

(0.157 in)

4.15-4.25 mm (0.163-0.167 in) E8TZ-7029-B 4.1 mm

(0.161 in)



15. Calculate and select the correct countershaft spacer. Refer to the Countershaft Spacer Selective Chart. Countershaft Spacer Equation Chart

Countershaft Spacer Selective Chart

16. NOTE: If necessary, apply a light coat of grease to the countershaft spacer, shim and fluid baffle.

Position the bearing shim, the fluid baffle and the countershaft spacer onto the front bearing retainer. � Using gasket maker, apply a thin coat to the sealing surface of the case and the front bearing retainer.

17. NOTE: To prevent damage to the fluid seal lip during assembly, tape the input shaft splines.

NOTE: Apply silicone sealant to the bolt threads.

Install the front bearing retainer and the 6 front bearing retainer bolts. � Tighten to 19 Nm (168 lb-in). � Remove the tape from the input shaft splines.

18. Position the oil passage.

Step Measurement mm (in)

Line 1 (Dimension C)

Line 2 (Dimension D)

Line 3 (add line 1 and line 2)

Total From Line 3 Part Number Thickness

2.45-2.55 mm (0.096-0.100 in) E8TZ-7C434-A 2.3 mm

(0.090 in)

2.55-2.65 mm (0.100-0.104 in) E8TZ-7C434-B 2.4 mm

(0.094 in)

2.65-2.75 mm (0.104-0.108 in) E8TZ-7C434-C 2.5 mm

(0.098 in)

2.75-2.85 mm (0.108-0.112 in) E8TZ-7C434-D 2.6 mm

(0.102 in)

2.85-2.95 mm (0.112-0.116 in) E8TZ-7C434-E 2.7 mm

(0.106 in)

2.95-3.05 mm (0.116-0.120 in) E8TZ-7C434-F 2.8 mm

(0.110 in)

3.05-3.15 mm (0.120-0.124 in) E8TZ-7C434-G 2.9 mm

(0.114 in)

3.15-3.25 mm (0.124-0.127 in) E8TZ-7C434-H 3.0 mm

(0.118 in)

3.25-3.35 mm (0.127-0.132 in) E8TZ-7C434-J 3.1 mm

(0.122 in)



19. NOTE: Apply silicone sealant to the bolt threads.

Install the front oil cooler tube bolt. � Tighten to 9 Nm (80 lb-in).

20. Install the output shaft 5th gear.

21. Install the locking ball.

22. Install the race and the 5th gear split needle bearing on the countershaft.

23. Install the countershaft 5th gear and the countershaft 5th gear synchronizer blocking ring.



24. NOTE: The reference mark on the synchronizer sleeve must face toward the reverse gear.

Install the 5th/reverse shift rail, the shift fork, and the synchronizer as an assembly.

25. Install the 5th/reverse shift lever into the case.

26. Install the counter lever shaft assembly. � Tighten to 45 Nm (33 lb-ft). � Install the plate with the arrow pointing downward. The chamfer points upward on the shaft assembly.

27. Install the 5th/reverse gear shift rail bolt. � Tighten to 25 Nm (18 lb-ft).

28. Install the synchronizer split washer.

29. Using a feeler gauge, check the clutch hub end play. � If the clutch hub end play is not within specification, select and install the correct split washer.

Split Washer Select Chart

Part Number Thickness

E8TZ-7R482-A 3.0 mm (0.118 in)



30. The reverse gears are not serviced separately. A kit consisting of the output shaft reverse gear, the countershaft reverse gear and the reverse idler gear is available for service. All 3 gears in the kit must be installed. The replacement gears are not compatible with the existing gears.

1. Output shaft reverse gear. 2. Countershaft reverse gear. 3. Reverse idler gear.

31. Install the following: � Thrust washer � Two countershaft reverse gear needle bearings � Countershaft reverse gear

32. Measure the countershaft reverse gear end play. � Install the thrust washer and hold it against the shoulder on the countershaft while checking the end play. � Determine the correct thrust washer to obtain the correct end play. Remove the reverse gear and install the appropriate thrust washer. Reinstall the reverse gear.

Thrust Washer Select Chart

33. Install the output shaft spacer.

E8TZ-7R482-B 3.1 mm (0.122 in)

E8TZ-7R482-C 3.2 mm (0.125 in)

E8TZ-7R482-D 3.3 mm (0.129 in)

E8TZ-7R482-E 3.4 mm (0.133 in)

E8TZ-7R482-F 3.05 mm (0.120 in)

E8TZ-7R482-G 3.15 mm (0.124 in)

E8TZ-7R482-H 3.25 mm (0.127 in)

E8TZ-7R482-J 3.35 mm (0.131 in)

E8TZ-7R482-K 3.45 mm (0.135 in)

E8TZ-7R482-L 3.50 mm (0.137 in)

Part Number Thickness

E8TZ-7C340-A 7.45 mm (0.293 in)

E8TZ-7C340-B 7.65 mm (0.301 in)

E8TZ-7C340-C 7.85 mm (0.309 in)

E8TZ-7C340-D 7.35 mm (0.289 in)

E8TZ-7C340-E 7.55 mm (0.297 in)

E8TZ-7C340-F 7.75 mm (0.305 in)



34. Install the output shaft reverse gear.

35. Install the reverse idler gear.

36. NOTE: Reverse idler shaft bolt must be installed within 4 minutes after applying the thread sealant with PTFE.

Install the reverse idler shaft bolt. � Tighten to 98 Nm (72 lb-ft). � Apply thread sealant to the reverse idler shaft bolt threads.

37. Using the Bearing Shaft Collar Installer (308-031), Bearing Shaft Collar Installer (308-035), Bearing Tube Remover/Installer and the Gear Spacer, install the output shaft rear bearing.

38. Install the thrust washer and the countershaft rear bearing.



39. Lock the transmission into 1st and 3rd gear.

40. Install a new countershaft locknut. � Tighten to 162 Nm (119 lb-ft).

41. Using the Transmission Shaft Locknut Socket, install a new output shaft rear bearing locknut. � Tighten to 216 Nm (159 lb-ft).

42. Using the Locknut Staking Tool, stake the output shaft rear bearing locknut and the countershaft locknut.

43. Install the locating ball, tone wheel and the tone wheel snap ring.



44. Apply gasket maker to the mating surface of the extension housing. Install the extension housing and the 8 extension housing bolts. � Tighten to 39 Nm (29 lb-ft).

45. Using the Transmission Extension Housing Oil Seal Installer, install the extension housing seal.

46. Place the synchronizer sleeves in neutral.

47. Install the case cover gasket.

48. Install the case cover and the 10 case cover bolts. � Tighten to 19 Nm (168 lb-in).



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