Therefore, the set of tools necessary for a major overhaul includes pliers for mounting washers, a bearing puller, a wooden hammer, a set of pin punches, a dial indicator and a hydraulic press. In addition, a large stable workbench or a stand for the box will be required.
As you disassemble the box, remember how each part comes off, where it contacts other parts, and what holds it in place. A 3D view (see pictures) is included to show where parts are located.
5.4, a. Three-dimensional image of gearbox shafts.
1. Shaft seal.
2. Outer ring of roller bearing.
3. Front shaft bearing.
4. Primary shaft.
5. Rear shaft bearing.
6. Outer ring of roller bearing.
7. Bearing preload ring.
8. 5th gear plug.
9. Outer ring of roller bearing.
10. Front bearing of 5th gear shaft.
11. 5th gear drive shaft.
12. Synchronizer locking insert.
13. Synchronizer retaining intermediate ring.
14. Synchronizer retaining spring.
15. 5th gear synchronizer hub.
16. 5th gear synchronizer cracker.
17. 5th gear synchronizer clutch.
18. Synchronizer retaining spring.
19. Synchronizer locking ring.
20. 5th gear pinion.
21. Rear bearing of 5th gear shaft.
22. Outer ring of roller bearing.
23. Bearing preload ring.
24. Main shaft plug.
25. Outer ring of roller bearing.
26. Front bearing of secondary shaft.
27. Secondary shaft.
28. 1st gear pinion.
29. Synchronizer locking ring.
30. Synchronizer retaining spring.
31. 1st and 2nd gear synchronizer hub.
32. Locking cracker of the hub of the synchronizer of the 1st and 2nd gear.
33. Reversible sliding gear.
34. Synchronizer retaining ring.
35. Synchronizer locking ring.
36. 1st and 2nd gear retaining ring.
37. 2nd gear pinion.
38. Thrust lock washer for 2nd and 3rd gear.
39. Thrust washer 2nd and 3rd gear.
40. 3rd gear pinion.
41. Synchronizer locking ring.
42. Synchronizer retaining spring.
43. 3rd and 4th gear synchronizer hub.
44. 3rd and 4th gear synchronizer hub cracker.
45. 3rd and 4th gear synchronizer clutch.
46. Synchronizer retaining spring.
47. Synchronizer locking ring.
48. Synchronizer ring for 3rd and 4th gear.
49. 4th gear pinion.
50. Secondary shaft bearing.
51. Outer ring of roller bearing.
52. Bearing preload spring.
53. Clutch housing.
54. Reversing light switch.
55. Reverse lever.
56. Reverse relay lever pivot pin.
57. External locking pin.
58. Gear shift selector pin.
5.4, b. Three-dimensional image of the manual transmission housing and associated elements.
59. Shift lever.
60. Ball.
61. Reverse lock pin.
62. Spring for setting the lever to the 3rd and 4th gear positions.
63. Shift lever shaft.
64. Shift shaft pin.
65. Shift lever shaft seal.
66. Shift linkage mounting bolt.
67. Shifter plate.
68. Selector lever pin.
69. Shift lever selector pin.
70. Shift selector lever.
71. Inner shaft of the switch.
72. Shift shaft lock plunger.
73. Shift shaft lock spring.
74 Shift shaft seal.
75. Shift shaft boot.
76. Shift fork roller cracker.
77. Pin that switches on the reverse lever relay.
78. Fork roller.
79. Fork of 1st and 2nd gear.
80. Support coupling.
81. Pin.
82. Fork selector lever.
83. Fork of 3rd and 4th gear.
84. 5th gear shift relay lever.
85. Reverse switch relay lever pin.
86. 5th gear relay lever pivot pin.
87. External retaining ring pin.
88. 5th gear fork.
89. 5th gear fork locking pin.
90. Control shaft of 5th gear fork.
91. Reverse gear shaft.
92 Reverse gear sleeve.
93. Reverse gear.
94. Dirt-catching magnet.
95. Gearbox housing.
96. Soapun.
97. Filler plug.
98. Reverse gear shaft lock bolt.
99. Lock plunger lock screw.
100. Shift fork shaft lock plunger.
101. Shift fork shaft lock spring.
102. Support coupling locking screw.
103. Gearbox housing bolt.
104. Differential seal.
105. Retaining ring.
106. Outer ring of differential bearing.
107. Differential bearing assembly.
108. Thrust washer of axle gear.
109. Half-axle gear.
110. Satellites.
111. Satellite thrust washers.
112. Satellite roller.
113. Satellite stopper.
114. Driven gear of the main transmission.
115. Left side of the differential housing.
116. Right side of differential housing.
117. Rivet of the housing and gear of the main transmission.
118. Speedometer gear.
119. O-ring seal.
120. Speedometer gear stopper.
121. Seal between the speedometer gear stopper and the housing.
122. Speedometer driven gear.
123. The mounting pin connecting the clutch housing to the gearbox housing.
124. Shift lever pawl spring.
125. Drive lever support bracket.
126. Reverse lock pawl pivot pin.
127. 5th gear and reverse spring.
128. Shifter plate dog.
129. Ball.
130. C-shaped retainer.
131. Ball.
132. Reverse switch relay lever.
133. Reverse switch relay spring.
134. Gearbox inspection window plug.
135. Felt washer.
136. Upper sleeve of clutch release shaft.
137. Thrust bearing fork lock bolt.
138. Clutch release shaft.
139. Clutch release shaft lever.
140. Thrust bearing fork.
141. Lower sleeve of the clutch release shaft.
(The original source of this article can be found at: fordbook)