DEMO - T5 Overdrive Manual Transmission

Ford Parts and Service DivisionTraining and Publications DepartmentOfficialLicensedProductLicense #2013226

Copyright 2014, Forel Publishing Company, LLC, Woodbridge, VirginiaAll Rights Reserved. No part of this book may be used or reproduced in any manner whatsoeverwithout written permission of Forel Publishing Company, LLC. For information write to ForelPublishing Company, LLC, 3999 Peregrine Ridge Ct., Woodbridge, VA 22192T5 Overdrive Manual TransmissionEAN: 978-1-60371-200-2ISBN: 1-60371-200-3Forel Publishing Company, LLC3999 Peregrine Ridge Ct.Woodbridge, VA 22192Email address: sales@ForelPublishing.comWebsite: http://www.ForelPublishing.comThis publication contains material that is reproduced and distributed under a license from FordMotor Company. No further reproduction or distribution of the Ford Motor Company material isallowed without the express written permission of Ford Motor Company.Note from the PublisherThis product was created from the original Ford Motor Company’s publication. Every effort hasbeen made to use the original scanned images, however, due to the condition of the material;some pages have been modified to remove imperfections.DisclaimerAlthough every effort was made to ensure the accuracy of this book, no representations orwarranties of any kind are made concerning the accuracy, completeness or suitability of theinformation, either expressed or implied. As a result, the information contained within this bookshould be used as general information only. The author and Forel Publishing Company, LLCshall have neither liability nor responsibility to any person or entity with respect to any loss ordamage caused, or alleged to be caused, directly or indirectly by the information contained inthis book. Further, the publisher and author are not engaged in rendering legal or otherprofessional services. If legal, mechanical, electrical, or other expert assistance is required, theservices of a competent professional should be sought.

IMPORTANT SAFETY NOTICEAppropriate service methods and proper repair proceduresare essential for the safe, reliable operation of all motorvehicles as well as the personal safety of the individualdoing the work. This program provides general directionsfor accomplishing service and repair work with tested,effective techniques. Following them will help assurereliability.There are numerous variations in procedures, techniques,tools, and parts for servicing vehicles, as well as in the skillof the individual doing the work. This publication cannotpossibly anticipate all such variations and provide advice orcautions as to each. Accordingly, anyone who departs fromthe instructions provided in this publication must firstestablish that he compromises neither his personal safetynor the vehicle integrity by his choice of methods, tools orparts.NOTES, CAUTIONS, AND WARNINGSAs you read through the procedures, you will come acrossNOTES, CAUTIONS, and WARNINGS . Each one is there fora specific purpose. NOTES give you added information thatw ill help you to complete a particular procedure. CAUTIONSare given to prevent you from making an error that coulddamage the vehicle. WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury. The following list contains some generalWARNINGS that you should follow when you work on avehicle. Always wear safety glasses for eye protection. Use safety stands whenever a procedure requires you tobe under the vehicle. Be sure that the ignition switch is always in the OFFposition, unless otherwise required by the procedure. Always block the wheels and set the parking brake whenworking on the vehicle. If you have a manual transmission, it should be inNEUTRAL unless instructed otherwise for a specific service operation. Operate the engine only in a wel l-ventilated area to avoidthe danger of carbon monox ide. Keep yourself and your clothing away from movingparts, when the engine is running, especially the fan andbelts. Remove neckties and tie long hair securely behindthe head.· To prevent serious burns, avoid contact with hot metalparts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler.WARNING: Do not smoke, carry lighted tobacco or anopen flame of any type when working on or near any fuelrelated component. Highly flammable mixtures arealways present and may be ignited, resulting in possiblehuman injury. To avoid damage to the vehicle and persona l injury,always remove rings, watches, loose hanging jewelry,and loose clothing before beginning to work on avehicle. Keep hands and other objects clear of the radiator fanblades! The electric cooling fan on some engines ismounted beh ind the radiator and can start to operate atany time by an inc rease in underhood temperatu re, eventhough the ignition switch position may be off. For thisreason care should be taken t 6 ensure that the electriccooling fan motor is completely disconnected whenworking under the hood, unless otherw ise requi red bythe procedure.Copyright 1982, Ford Motor Company\

TS OD MANUAL TRANSMISSIONDESCRIPTIONTABLE OF CONTENTSThe TS is a five speed manual transmission with fifth speed as anoverdrive gear. First through fourth and reverse gears mesh within thecase. The fifth speed gears and synchronizer are located on the backof the case in the extension housing. The floor mounted shift leveroperates a shift rail which extends from the extension housing turretto the shift cover. The first-second and third-fourth shift forks aremounted in the cover. The fifth speed synchronizer and reverse slidinggear are shifted through an intermediate lever mounted on a pivot pin.A shift interlock system, located in the cover, prevents engagement ofmore than one gear. The shift detent is located in the extension housing turret and consists of a detent plate, offset lever and spring loadedball. All gears, except reverse, are synchronized and helical cut forsmooth, crisp shifts and quiet operation. Reverse is provided througha reverse idler gear whic h slides along a shaft to engage spur gears onthe countershaft and output shaft. The case is aluminum and allfasteners are metric.DESCRIPTION . . . 1GEARTRAIN COMPONENTS . . . . . . . . . . . . . . . . 2POWER FLOWFirst Gear . . . . . . . . . 3Second Gear . . . . . . . 3Third Gear . . . . . . . . . . 4Fourth Gear . . . . . . . . . . . . . . . . . . . 4Fifth Gear . . . . . . 5Reverse . . . . . . . . . . . . . . . . . . . . 5DISASSEMBLED VIEW . . . . . 6TRANSMISSION DISASSEMBLY . . . . . . . 8TRANSMISSION SUBASSEMBLIESOutput Shaft Disassembly . . . . . . . . . . . . . 19Synchronizer Di sassembly and Assembl y . . . . . 22Output Shaft Assembly . . : . . . . . . . . . . . 24Shift Cover Disassembly and Assembly . . . 27Bearing Retainer Seal Removal and Installation . . . . . . . 30Input Shaft Bearing Removal and In stallation . . . . . . . . 31Extension Housing Seal Removal and Install at ion . . . . 32Extension Hou sing Bushing Removal and Installati on . . . 33Countershaft Front Bearing Removal and Installation . . . 34TRANSMISSION ASSEMBLY . . . . . . . . 35SPECIFICATIONS . In side Back Cover1

TS OD MANUAL TRANSMISSIONGEARTRAIN RIVEN GEARFIFTHGEARDRIVENINPUT GEARDRIVING(FOURTH GEAR)- NG2FIFTHGEARDRIVINGFIFTHGEARSYNCHRONIZER

TS OD MANUAL TRANSMISSIONPOWERFLOWFirst Gear1·2 SYNCHRONIZERSHIFTED REARWARDRatio:2.95:1 4.03:1 -5.0 Liter Engine2.3 Liter Turbocharged Engine 1-2 synchronizer is splined to output shaft. When synchronizer sleeve is shifted rearward, first gear is lockedto output shaft through the synchronizer. Input gear is driving countershaft. First gear on countershaft drives first gear on output shaft. Output shaft is driven in reduction .Second Gear1·2 SYNCHRONIZERSHIFTED FORWARDRatio:-31.94:1 2.37:1 -5.0 Liter Engine2.3 Liter Turbocharged Engine 1-2 synchronizer is splined to output shaft. When synchronizer sleeve is shifted forward, second gear is locked to output shaft through the synchronize r. Input gear is driving countershaft. Second gear on countershaft drives second gear on output shaft. Output shaft is driven in reduction .

TS OD MANUAL TRANSMISSIONPOWERFLOW (continued)Third Gear3.4 SYNCHRONIZERSHIFTED REARWARDRatio:1.34:1 1.50:1 -5.0 Liter Engine2.3 Liter Turbocharged Engine 3-4 synchronizer is splined to output shaft. When synchronizer sleeve is shifted rearward, third gear is lockedto output shaft through the synchronizer. Input gear is driving countershaft. Third gear on countershaft drives third gear on output shaft. Output shaft is driven in reduct ion.Fourth Gear3·4 SYNCHRONIZERSHIFTED FORWARDRatio:.41:1 1:1 -5.0 Liter Engine2.3 Liter Turbocharged Engine 3-4 sync hron izer is sp lined to output shaft. When synchronizer sleeve is shifted forward, input shaft is lockedto output shaft through the synchro nizer. Th e separate shafts are now linked into a si ng le shaft. Output and input shafts are driven at the same speed.

TS OD MANUAL TRANSMISSIONPOWERFLOW (continued)Fifth GearRatio:0.73:1 0.86:1 -5.0 Liter Engine2.3 Liter Turbocharged Engine Fifth gear sync hronizer is splined to countershaft. When synchronizer sleeve is shifted forward, fifth gear is locked tothe countershaft. Input gear is driving countershaft. Fifth gear on countershaft drives fifth gear splined to outpu t shaft. Output shaft is driven in overdrive.FIFTH GEARSYNCHRONIZERSHIFTEDFORWARDReverseREVERSE IDLERGEAR SHIFTEDREARWARDRatio:52.76:1 3.76:1 -5.0 Liter Engine2.3 Liter Turbocharged Engine To reverse output shaft rotation, an idler gear is shifted into position between the reverse gear on the cou nters haft and the reversegear on the output shaft. The reverse gear on the output shaft is part of the 1-2 sync hron izerwhich is splined to the output shaft. The input gear is driving the countershaft. The countershaft drives the reverse idler. The idl er gear reverses the rotation of the output shaft and drivesit in reduction.

- lTS OD MANUAL TRANSMISSIONDISASSEMBLED VIEW.6