Ford Mustang 2005 User Manual

IMPORTANT SAFETY NOTICE

Appropriate service methods and proper repair procedure are essential for the safe, reliable operation of all motor
vehicles as well as the personal safety of the individual doing the work. This Manual provides general directions for
accomplishing service and repair work with tested, effective techniques. Following them will help assure reliability.
There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill
of the individual doing the work. This Manual cannot possibly anticipate all such variations and provide advice or
cautions as to each. Accordingly, anyone who departs from the instructions provided in this Manual must first
establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods, tools or
parts.

NOTES, CAUTIONS, AND WARNINGS

 As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each

one is there for a specific purpose. NOTES give you added information that will help you to complete a
particular procedure. CAUTIONS are given to prevent you from making an error that could damage the
vehicle. WARNINGS remind you to be especially careful in those areas where carelessness can cause
personal injury. The following list contains some general WARNING that you should follow when you work
on a vehicle.

 Always wear safety glasses for eye protection.

 Use safety stands whenever a procedure requires you to be under the vehicle with the vehicle jacked up.

 Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure.

 Set the parking brake when working on the vehicle. It should be in REVERSE (engine OFF) or NEUTRAL

(engine ON) unless instructed otherwise for a specific operation. Place wood blocks (4”X4” or larger) to the
front and rear surfaces of the tires to provide further restraint from inadvertent vehicle movement.

 Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide.

 Keep yourself and your clothing away from the moving parts, when the engine is running, especially the fan

and drive belts.

 To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold tail pipe,

catalytic converter and muffler.

 Do not smoke while working on the vehicle.

 To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning

to work on a vehicle. Tie long hair securely behind the head.

 Keep hands and other objects clear of the radiator fan blades, Electric cooling fans can start to operate at any

time by an increase in under hood temperatures, even though the ignition is in the OFF position. Therefore,
care should be taken to ensure that the electric cooling fan is completely disconnected when working under
the hood.

Disconnect the negative battery ground cable before using any electric welding equipment.



Contents

Section Page

1

2

3

4

5

6

INTRODUCTION AND DESCRIPTION

1-1. Introduction ……………………………………………………………………….
1-10. Description………………………………………………………………………

T5 WC & STD ON-VEHICLE SERVICE AND TROUBLESHOOTING

2-1. Maintenance……………..………………………………………………………..
2-7. Troubleshooting…………………………………………………………………..
2-10. Transmission Removal… ………………………………………………………
2-21. Transmission Installation ………………………………………………………..

T5 WC DISASSEMBLY

3-1. General Information ……………………………………………………………...
3-6. T5 HD Transmission Disassembly Procedures ………………………………

T5 STD DISASSEMBLY

4-1. General Information ……………………………………………………………...
4-6. T5 STD Transmission Disassembly Procedures ……………………………..

T5 WC & STD CLEANING, INSPECTION, REPAIR OR REPLACEMENT

5-1. Cleaning …………………………………………………………………………..
5-5. Inspection …………………………………………………………………………
5-10. Repair or Replacement ………………………………………………………….

T5 WC ASSEMBLY

6-1. General Information ……………………………………………………………...
6-4. T5 HD Transmission Assembly Procedures …………………………………..

1-1
1-1

2-1
2-1
2-4
2-7

3-1
3-1

4-1
4-1

5-1
5-8

5-16

6-1
6-1

7

T5 STD ASSEMBLY

7-1 General Information ……………………………………………………………...
7-4. T5 STD Transmission Assembly Procedures ………………………………...

7-1
7-1

Section 1

Introduction and Description

1-1. INTRODUCTION
1-2. PURPOSE. This manual contains

maintenance, service and parts information for the
T5 Five-Speed Manual Transmission manufactured
by TREMEC (TRANSMISIONES Y EQUIPOS
MECANICOS S.A DE C.V.) Av. 5 de febrero No.
2115, Querétaro,Qro. México.

1-3. SCOPE. As you will see in the Table of
Contents, this manual provides information for
maintenance, troubleshooting, disassembly,
cleaning, inspection, repair or replacement, and
assembly of the transmission.

1-4. T5 TRANSMISSION CLASSES. Two
basic T5 transmission classes are covered in this
manual: WC (world class) and STD (standard).
Separate disassembly (Section 3 and 4) and
assembly (Sections 6 and 7) instructions are
provided for each of these classes. In other section
of the manual, variations within the classes are
noted in the instructions and illustrations.

NOTE

The parts shown in the illustrations in the service
instructions are typical for those used in a particular
class of transmission (WC or STD). Some parts may
be encountered in service that are different in
appearance than those illustrated. These “different”
parts perform the same function as those illustrated.

1-5. T5 TRANSMISSION CLASS
IDENTIFICATION. The T5 transmission can be

identified as WC or STD by the last three digits of
the transmission part number (see Table 3-1 or 4-1
in the disassembly sections). In this manual, figure
titles, lists, tables and main paragraph headings are
in the proper section for the transmission being
serviced.

1-6. PART IDENTIFICATION. Each detail part
shown in the exploded views in this manual for a
particular transmission class (WC or STD) is
assigned an index number. This same index
number is used to identify the part throughout this
manual. For example, WC index number 116 (in
parenthesis in the text) refers to the countershaft
gear in all applicable sections. The same is true for
STD index number 105.

1-7. The exploded view illustration in Section 5 (figure
5-1 or 5-2) make it possible to view the complete
transmission assembly in addition to the illustrations
in the Sections 3,4,6 and 7 relating to a specific
disassembly or assembly procedure.

1-8. PART NUMBERS. The purpose of the index
numbers in the illustrations in this manual is to identify
parts. Part numbers are not used. Once a part is
identified, refer to the TREMEC T5 Transmission
Parts Catalog for the correct part number.

1-9. ABBREVIATIONS. Abbreviations, other than
those in common use, found in this manual are
identified in Table 1-1.

1-10. DESCRIPTION

1-11. TRANSMISSION DESCRIPTION. The

TREMEC Automotive T5 is a five speed,
countershaft, helical gear transmission . It is fully
synchronized for ease of shifting. Gear ratios vary
from model to model (refer to vehicle service manual
for specifications.) The input and output ends of the
input and output shafts are supported by tapered
roller bearings. A pilot roller bearing is used between
the input and output shafts. The countershaft gear is
supported in tapered roller bearings for WC models
and straight roller beatings for STD models. These
and other basic differences in the two classes are
shown in Table 1-2.

1-12. APPLICATION. The T5 transmission is used on
sports cars, small to medium sedans and coupes,
compact trucks and vans, utility vehicles and similar
2-wheel and 4-wheel drive vehicles.

Table 1-1. Abbreviations

AR As Required
Assy Assembly
ID Inside Diameter
NP Not Procurable
OD Outside Diameter
PN Part Number
QTY Quantity
TIR Total Indicator Reading

FEATURE DESCRIPTION

Bearings under gears
Blocking rings
Countershaft bearings

Table 1-2. Basic Differences Between T5 WC and STD Classes

WC STD

Needle bearings
Fiber synchronizers
Tapered roller bearings

1-1

Journals
Brass synchronizers
Straight roller bearings

Section 2

T5 WC & STD On- Vehicle Service and Troubleshooting

2-1. MAINTENANCE
2-2 GENERAL. The only periodic maintenance

required for the TREMEC T5 transmission is to
maintain proper lubrication.

2-3. LUBRICATION SCHEDULE. Refer to the
Vehicle Owner’s Manual or Service Manual.

CAUTION

Excessive temperatures may bread down the
transmission lubricant (refer to vehicle service
manual for maximum allowable temperature). If there
is reason to believe that the transmission has been
subjected to temperatures exceeding 275° F, change
the lubricant immediately.

2-4. APPROVED LUBRICANT. Most T5

transmission models use Dexron II automatic
transmission fluid. Refer the vehicle owner’s manual
or service manual for lubricant specifications.

CAUTION

Do not mix different bands or types of transmission
lubricant. DO NOT USE GEAR OIL IN THE T5
TRANSMISSION SINCE THIS MAY DAMAGE THE
BLOCKING RING MATERIAL.

2-5. CHECKING LUBRICANT LEVEL. Proceed as

follows (see figure 2-2):

NOTE

To check or drain the lubricant, the transmission
should be warm. This is best done shortly after
engine shutdown.

2-6. CHANGING LUBRICANT. Proceed as follows
(see figure 2-2):

a. Wipe drain and fill plugs (1 and 2) and

surrounding areas clean.
b. Place suitable container under transmission.
c. Remove drain plug (1).
d. Remove fill plug (2).
e. Allow all lubricant to drain.
f. Install drain plug (1) and torque to 20 lb-ft

(27 Nm).
g. Add lubricant Through fill plug opening until

lubricant just begins to drip back out of opening.

NOTE

The amount of lubricant required varies from model

to model. Refer to the vehicle service manual for
transmission capacity.

h. Install fill plug and torque to 20 lb-ft (27 Nm).

2-7. TROUBLESHOOTING
2-8. GENERAL. In the event of operating difficulty,

it is recommended that the transmission (engine) be
shut down. In most cases, to accurately pinpoint the
source of trouble, it may be necessary to remove
and disassemble, or partially disassemble, the
transmission. Specific inspection procedures for
detail parts of the transmission are provided in
Section 5.

2-9. TROUBLESHOOTING CHART. Table 2-1 lists
troubles which may be encountered along with
possible causes and remedies.

a. Wipe fill plug (2) and surrounding area clean.
b. Remove fill plug (2).
c. When transmission is full, lubricant will just drip

out fill plug opening.
d. Add approved lubricant if required.
e. Install fill plug (2) and torque to 20 lb-ft (27 Nm).

2-1

Table 2-1. Troubleshooting Chart

PROBLEM POSSIBLE CAUSE REMEDY

Will not shift
(control lever
moves)

Hard shift or
control lever will
not move into
gear

Control lever assy broken or damaged
Damaged offset lever, shift fork, selector

Plate or selector arm
Clutch not releasing
Improper or low transmission lubricant

Replace control lever and housing assy
Remove extension or adapter and case

Cover. Check for damaged parts. Replace
Damaged parts
Adjust or replace clutch

Add or drain and replace with proper
Lubricant (refer to paragraph 2-4

Gears clash when
Shifting

Shifter shaft or shift rail binding

Binding of sliding synchronizers or gears

If reverse only, seized backup switch

Worn or damaged flywheel pilot bushing
Bell housing misaligned
Engine idle speed too high
Clutch damaged or out of adjustment
Pilot bearing between input shaft and

Output shaft binding

Damaged synchronizer

Bell housing misaligned

Remove extension or adapter and case
Cover. Check for damaged parts. Replace
Damaged parts

Remove extension or adapter and case cover.
Reach down into transmission and
Check that synchronizers and gears (parts
With shifting grooves) slide freely on shafts.
Remove and replace damaged parts.

Remove and check backup switch.
Replace if seized

Replace pilot bushing
Align bell housing to within 0.010 inch

TIR on face and in bore.
Adjust idle speed to specifications

Adjust or replace clutch
Disassemble and check bearing rollers,

Input shaft ID and output shaft OD.
Replace damaged parts

Disassemble and check for damaged
Synchronizer parts. Replace damaged parts

Align bell housing to within 0.010 inch
TIR on face and in bore

Transmission
jumps out of gear

Damaged gear or gears

Worn or damaged flywheel pilot bushing
Loose transmission or flywheel housing
Bolts, improper alignment

Synchronizer damaged or excessively worn

Blocking ring damaged, worn index slots
Or friction surfaces worn or damaged

Excessive countershaft end play

Shifting fork loose on shaft or rail; worn
Or damaged fork or inserts

2-2

Disassemble and check for gear damage.
Replace damaged gears

Replace pilot bushing
Torque bolts to specifications. Realign if
Necessary

Disassemble and check for worn or
Damaged synchronizer parts. Replace
Damaged parts

Disassemble and check blocking ring for
Damaged parts

Disassemble and check. Replace worn or
damaged parts. Reshim if roller bearings
Used.

Disassemble and check for wear or
Damage.

Table 2-1. Troubleshooting Chart (Cont)

PROBLEM POSSIBLE CAUSE REMEDY

Transmission
locked in one
gear

Fork or offset lever loose on shaft or rail

Remove extension or adapter and case
Cover. Check for loose parts on shifter
shaft or rail. Replace roll pin(s). If still
loose, replace shaft or rail and/or
attached parts as required

Transmission
noise. NOTE:
Make sure noise
is coming from
transmission and
not clutch release
bearing or other
components.

Worn or damaged forks, offset lever,
Shaft or rail

Worn or damaged synchronizer

Worn or damaged gears

Improper or low transmission lubricant

Loose bolts or other attaching parts

Improper flywheel housing to engine
crankshaft alignment

Noisy transmission bearings

Remove extension or adapter and case
Cover. Check for wear or damage,
Replace damaged parts

Disassemble and check for worn or
damaged synchronizer parts. Replace
worn or damaged parts

Disassemble and check for worn or
damaged gears. Replace worn or
damaged gears

Add or drain and replace with proper
lubricant (refer to paragraph 2-4)

Make sure al attaching parts are torqued
to specifications

Check alignment and correct if necessary
per vehicle service manual

Disassemble and check bearing, bearing
rollers and parts in and on which
they operate for wear or damage.
Replace worn or damaged parts

Transmission
leakage

Noisy gears

Leakage from other components

Vent or breather clogged

Too much or improper lubricant

Loose bolts at sealing faces
Improperly applied sealant

Worn or damaged oil seal

Disassemble and check for worn or
damaged gears (including speedometer
gear). Replace worn or damaged gears

Verify transmission leakage. Thoroughly
clean all exposed surfaces, then check
for leaks

Remove vent or breather and clean or
replace

Remove fill plug to check for excess, or
drain and replace

Torque bolts to specifications
Separate and thoroughly clean leaking

surfaces. Reapply sealant. Replace parts
and torque bolts to specifications

Replace oil seal

2-3

2-10. TRANSMISSION REMOVAL
2-11. GENERAL. The following paragraphs provide

procedures for removing the T5 transmission. For 4-wheel
drive vehicles, instructions are also given for removing the
transfer case. If the vehicle is not equipped with 4-wheel
drive, disregard paragraph 2-18 and references to the
transfer case in the other paragraphs

2-12. OTHER COMPONENTS. Before or during
transmission removal, it may be necessary to remove or
disconnect other components. This is required to provide
access to or clearance for the transmission ( and transfer
case, if used ). Since these components vary widely from
vehicle to vehicle, specific instruction are not provided in this
manual. Refer to the vehicle service manual. Such
components may include:
a. Console or similar cover.
b. Parking brake lever and controls.
c. Wiring and/or vacuum harness.
d. Exhaust system components.
e. Clutch components.
f. A skid plate or protective covers on the underside of the

vehicle.

1.13 SUPPORTING TRANSMISSION ( OR TRANSFER
CASE, IF USED) Before removing any parts which attach or

support the transmission(and transfer case, if used), support
the transmission on a suitable jack or stand. The jack or
stand must be capable of supporting and holding the
transmission independently. Also the jack or stand shall be
capable or lowering, raising and moving the transmission
laterally.

2-14. PROCEDURES WITH VEHICLE ON FLOOR. Before
raising the vehicle, proceed as follows:
a. Position vehicle over suitable hoist.

WARNING
When using a drive-on lift, be sure to properly chock the
wheels to prevent the vehicle from rolling off.

b. Disconnect negative battery terminal.
c. Shift vehicle into neutral and release parking brake. On

4-wheel drive vehicles, shift into 4HI.

d. Remove shift lever (see figure 2-1):

1. Detach bottom of boot (1) so that it can be raised
to provide access to lower end of shift lever. Boot
attachment methods may vary from that shown.

2. If shift lever is threaded on, loosen lock nut (2),
then remove shift lever (4) using wrench on flats (5)
provided.

3. If shift lever is attached with screws (3), then
remove screws (3) and shift lever (4).

2-15. LIFTING VEHICLE. Lift vehicle on suitable hoist,
allowing clearance for removal of transmission (and transfer
case, if used), and related components such as propeller
shaft (or shafts), cross members and supports. If unsure,
refer to vehicle service manual for approved lift points.

NOTE
On some vehicles, it may be necessary to remove or
disconnect other components (refer to paragraph 2-12)

Figure 2-1. shift Lever

2-16. DRAINING LUBRICANT. Drain lubricant from

transmission (and transfer case, if used) (refer to
paragraph 2-6, steps a through e). Reinstall fill and drain
plugs.

2-17. REMOVING REAR PROPELLER SHAFT. The rear
propeller shaft (3, figure 2-2) is splined to the
transmission (or transfer case, if used) output shaft. It will
be necessary to disconnect the rear end of the propeller
shaft first, then move the shaft rearward to disengage the
splines. Support the propeller shaft to prevent it from
dropping. Bend universal joints just enough to permit
shaft removal. Otherwise damage may result. Refer to
the vehicle service manual for specific procedures.

2-4

Figure 2-2. Transmission

2-5

2-18. REMOVING TRANSFER CASE (4-WHEEL
DRIVE VEHICLES ONLY). On 4-wheel vehicles,

proceed as follows to remove transfer case (see
figure 2-3 and 2-4 and refer to WARNING
following paragraph 2-14, step a):
a. Remove front propeller shaft (17, figure 2-3) by

removing bolts (15) and retainers (16).
Observe same precautions in handling front
propeller shaft as for rear propeller shaft (refer
to paragraph 2-17).

b. Remove shift lever linkage and bracket

attached to transfer case and transmission.

c. Support transfer case on suitable jack or stand

(refer to paragraph 2-13).

CAUTION

Make sure transfer case is completely supported by

jack or stand before removing bolts (18,figure 2-4)
attaching transfer case to transmission. Do not
allow transfer case to “hang” from transmission by
splined shaft since this may damage input bearings.

d. Remove bolts (18) attaching transfer case (19)

to transmission (10).

e. Move transfer case (19) straight back toward

rear of vehicle to completely disengage splines
from transmission (10). Remove gasket (20).

f. Carefully lower transfer case on jack or stand.

2-19. REMOVING TRANSMISSION SUPPORT
BRACES. The main transmission attachment

points are at the clutch housing (4, figure 2-2) and
at the transmission mount (5) on the cross member
(6). Supplemental support braces may or may not
be used, depending on the vehicle. If used, remove
supplemental support braces and any other
components necessary to provide for transmission
clearance.

2-20. REMOVING TRANSMISSION. Proceed as

follows (see figure 2-2 and refer to warning following
paragraph 2-14, step a):
a. Support transmission on suitable jack or stand

(refer to paragraph 2-13).

b. Remove back-up switch electrical connection

(7). Also, if used, remove neutral switch
electrical connector or any others that may be
used.

c. Remove speed sensor electrical harness or

speedometer cable (location may vary).

d. Remove bolts (8) and lockwashers (9) attaching

transmission (10) to transmission mount (5).

e. Remove cross member (6).

CAUTION

Make sure transmission is completely supported by
jack or stand before removing bolts (11) attaching
transmission (10) to clutch housing (4). Do not allow
transmission to “hang” from clutch by splined shaft
since this may damage input bearings.

f. Remove bolts (11) attaching transmission (10) to

clutch housing (4).

g. Using care not to dislodge clutch parts, move

transmission (10) straight back toward rear of
vehicle to completely disengage splines from
clutch.

h. Carefully lower transmission (10) on jack or

stand.

Figure 2-3. Front Propeller Shaft

2-6

Figure 2-4. Transfer Case

2-21. TRANSMISSION INSTALLATION
2-22. GENERAL. Install Transmission (and transfer

case, if used) in vehicle from which it was removed as
described in the following paragraphs. Note the
following:

CAUTION
T5 transmissions are not necessarily
interchangeable from vehicle to vehicle. Installation
of the transmission in a vehicle other than that from
which it was removed may result in premature
failure.

a. The following paragraphs provide procedures for

installing the T5 transmission. For 4-wheel drive
vehicles, instructions are also given for installing the
transfer case. If the vehicle is not equipped with 4­wheel drive, disregard paragraph 2-24 and
references to the transfer case in the other
paragraphs.

b. Before or during removal of the transmission, parts

not specifically related to the transmission may
have been removed to provide access or clearance.
Be sure to reinstall these components exactly as
they were prior to removal (refer to paragraph 2-12).

c. The transmission (and transfer case, if used) must

be supported on a suitable jack or stand capable of
raising it the transmission into position, aligning
and moving it to engage the drive splines.

2-23. INSTALLING TRANSMISSION. Proceed as

follows (see figure 2-2):
a. Apply thin coat of high temperature grease to input

shaft spline on transmission (10).

b. Shift transmission (10) into high gear and raise on

jack or stand. Align transmission with clutch
housing(4).

CAUTION
Make sure transmission is in exact alignment with
clutch before engaging splines. Do not force
transmission input shaft into clutch. Otherwise
damage may result. If necessary, turn transmission
output shaft to align input shaft spline with that in
clutch.

c. Carefully move transmission (10) forward, engaging

splines in clutch, until transmission mounting flange
contacts clutch housing (4).

CAUTION
Keep transmission completely supported by jack or
stand until bolts (11) attaching transmission (10) to
clutch housing (4) are installed and torqued. Do not
allow transmission to “hang” from clutch by splined
shaft since this may damage input bearings.

d. Make sure mounting holes in transmission (10) and

clutch housing (4) are aligned and install bolts (11).
Torque bolts to 55 lb-ft (75 Nm). Do not remove jack
or stand at this time.

e. Install cross member (6). Install bolts (8) and

lockwashers (9) attaching transmission (10) to
transmission mount (5). Torque bolts to 35lb-ft (59
Nm).

d. Remove jack or stand supporting transmission .
e. Install speed sensor electrical harness or

speedometer cable (location may vary).

f. Install back-up switch electrical connection (7)

and any other electrical connectors that were
removed.

g. Install any supplemental supports or braces that

were removed during transmission removal.

WARNING
Be sure to fill transmission with proper fluid (refer
to paragraph 2-4). Otherwise transmission will be
damaged when engine is started. If vehicle is
driven, transmission could lock up causing
personal injury.

2-24. INSTALLING TRANSFER CASE (4-WHEEL
DRIVE VEHICLES ONLY). On 4-wheel drive vehicles,

proceed as follows to install transfer case (see figure
2-3 and 2-4):
a. Apply thin coat of high temperature grease to

output shaft spline on transmission (10, figure 2-

4).

b. Install new gasket (20) on transfer case (19)

mounting face.

c. Raise transfer case (19) on jack or stand. Align

transfer case with transmission (10).

CAUTION

Make sure transfer case is in exact alignment with

transmission before engaging splines. Do not
force transfer case onto transmission. Otherwise
damage may result. If necessary, turn transfer case
output shaft to align input shaft spline with that on
transmission.

d. Carefully move transfer case (19) forward,

engaging splines on transmission, until transfer
case mounting flange contacts transmission (10).

CAUTION

Keep transfer case completely supported by jack

or stand until bolts (18) attaching transfer case
(19) to transmission (10) are installed and torqued.
Do not allow transmission to “hang” from clutch
by splines shaft since this may damage input
bearings.

e. Make sure mounting holes in transmission (10)

and transfer case (19) are aligned and install bolts
(18). Torque bolts to 23 lb-ft (31 Nm). Remove
jack or stand.

f. Attach shift lever bracket and linkage removed at

transfer case removal.

g. Make sure front propeller shaft (17, figure 2-3) is

properly lubricated and install. Attach to transfer
case (19) with retainer (16) and bolts (15). Torque
bolts to 15 lb-ft (29Nm).

WARNING
Be sure to fill transfer case with proper fluid (refer
to vehicle service manual). Otherwise transfer
case will be damaged when engine is started. If
vehicle is driven, transfer case could lock up
causing personal injury.

2-7

2-25. INSTALLATION REAR PROPELLER
SHAFT. Proceed as follows (see figure 2-2):

a. Make sure rear propeller shaft (3) is properly

lubricated.

b. Apply thin coat of high temperature grease to

output shaft spline on transmission (10) (or
transfer case, if used).

c. Carefully insert front end of rear propeller shaft

(3) into transmission (10) (or transfer case, if
used). Use care not to damage oil seal (21).

d. Connect rear end of rear propeller shaft at

differential (refer to vehicle service manual for
specific instructions).

2-26. FILLING TRANSMISSION WITH
LUBRICANT. Fill transmission (and transfer case, if

used) with proper lubricant refer to paragraph 2-6,
steps f through h).

2-27. COMPLETION OF INSTALLATION.

a. Lower vehicle to floor.
b. Install shift lever (see figure 2-1):

1. If shift lever is attached with screws,
align screw holes in shift lever (4) and
transmission control lever and install
screws.

2. If shift lever is threaded on, screw shift
lever (4) onto transmission control lever.
Hold in desire position with wrench across
flats (5) and tighten nut (2) up against shift
lever (4) to 34 lb-ft (47 Nm).

3. Reattach bottom of boot (1).

c. Connect negative battery terminal.

2-8

Section 3

T5 WC Disassembly

3-1. GENERAL INFORMATION

3-2. This section provides disassembly instructions
for the T5 WC transmission. The transmission
class can be identified by the last three digits of
the transmission part number. WC units are listed in
Table 3-1. If the number for the transmission to be
disassembled is not listed in Table 3-1, refer to
Section 4, T5 STD Disassembly.

3-3. During disassembly, refer to the illustrations
provided with the text. In addition, an exploded
view of the complete assembly can be seen on
figure 5-1 in Section 5, Cleaning, Inspection,
Repair or Replacement.

3-4. This section provides instructions for complete
disassembly of the T5 WC transmission as would
be the case for overhaul. If the transmission is not
due for overhaul, and repair affecting specific parts
is required, disassemble only to the extent
necessary to gain access to these parts. Parts
removed from the transmission as subassemblies
or groups need not be disassembled for repair
unless they contain the affected parts. Total
disassembly is recommended to ensure that all
parts are absolutely clean.

3-5. REMOVAL AND INSTALLATION OF
TRANSMISSION. Refer to paragraphs 2-10 and 2-

21.

3-6. T5 WC TRANSMISSION DISASSEMBLY
PROCEDURES.

3-7. REMOVAL OF T5 HD CONTROL LEVER AND
HOUSING ASSEMBLY AND EXTERNAL
COMPONENTS. Clean transmission exterior if

necessary, support on suitable holding fixture and
proceed as follows (see figure 3-1):

a. Remove fill and drain plugs (1) and drain all fluid

from transmission.

b. Shift transmission into neutral at 3-4 position.

CAUTION

Failure to shift transmission into neutral at 3-4

position before removing control lever and
housing assembly may result in driving roll pin
(15, figure 3-2) into detent guide plate (18) when
pin is removed (paragraph 3-8).

c. Remove screws (2). If extended control lever

and housing assembly (3C) is used, also remove
screws (2A).

d. If necessary, use suitable knife to break sealant

bond between control lever and housing
assembly (2A, 3B, or 3C) and extension (17A) or
adapter (17B). Remove control lever and
housing assembly. Remove boot (4) only if
replacement is required.

e. Remove vent and o-ring assembly (5A) or

breather (5B).

f. As used, remove neutral switch (6), pin (7),

harness retainer (8), screw (9), speedo adapter
(10) roll pin (11), speedo driving gear (12) oil
seal (13) and o-ring (14).

114 thru 116

126
134
141
155
162

Table 3-1. T5 WC Transmissions

(Three Digits of Part Number: 1352-000-XXX)

165
167 thru 169
174 thru 177

184
194 thru 200
202 thru 205

3-1

207
229
238
247
248

249
251
254
258
260

Figure 3-1. T5 WC Control Lever Housing and External Components

3-2

3-8. REMOVAL OF T5 WC CONTROL SEMI­REMOTE. This only applies to transmissión

equipped with semi- remote control. With the
transmissión placed on a work bench, disassemble
the semi-remote control following these steps:
(see figure 3-2)
a. Remove bolts (2).
b. Revise the U joint insulator (129) if it too lose,

replace it.

c. To pull out the shift rod pins (141), first remove

the two snap rings (140) and washers (142)
and then remove the shift road (139).

d. Remove the inner shifter boot (134) and the

control lever (136) by pulling it off the lining
socket (137),

e. With the help of a small screwdriver remove

the arm control housing. (135) by removing the
pin & clip assy (130).

120. Assy remote shift 126. Lever offset, control 132. Sleeve U joint 138. Bushing arm hsg.

121. Grooved pin 127. Rail shift 133. Isolator U joint 139. Shift road

122. Oil seal 128. Spring bias 134. Boot shifter inner 140. Snap ring

123. Breather hose 129. Insulator U Joint 135. Arm control housing 141. Shift rod pin

124. Pin U Joint 130. Assy pin & clip 136. Lever control 142. Washer truarc

125. Cover shift tower 131. Retaining ring 137. Lining socket

Figure 3-2. T5 WC Control Semi-Remote

f. Using a punching tool, remove the U joint pin

(124) from the shift rail (127), inspect the U joint
sleeve (132) it should not be too lose. If
necessary remove the retaining ring (131) and
replace the U joint isolator (133).

g. To remove the shift rail (127) the grooved pin

(121) has to be removed first, to do this place
the cover assembly on its side and use a
punching tool.

h. Remove the bias spring (128) from the control

offset lever (126) and inspect for wear on the
speed selector.

i. Remove the shift tower cover (125) and inspect

for wear on the shift rail hole. Replace the
necessary.

j. If necessary to remove the oil seal (122), use a

small screw driver.

k. If necessary to remove the breather hose (123),

use a wrench.

3-3

3-9. REMOVAL OF T5 WC EXTENSION OR
ADAPTER. With offset lever accessible and in

neutral at 3-4 position (paragraph 3-7, step b),
proceed as follows (see figure 3-3):

a. Using suitable drift, drive roll pin (15) into offset

lever (20) and out of engagement with shifter
shaft (29). Tap drift with hammer just until

offset lever feels free on shaft.
b. Remove bolts (16).
c. If necessary, use suitable knife to break

sealant bond between extension or adapter

(17A or 17B) and transmission case (117). Pull

extension or adapter straight out from

transmission case. Offset lever (20) will slide

off shifter shaft (29) with extension or adapter.
d. Remove offset lever (20), damper sleeve (21),

spring (23), ball (22) and oil seal (24) from

extension (17A) or adapter (17B). Remove roll

pin (15) if loose or drive out of offset lever (20)

if still partially installed. Do not remove detent

guide plate (18) or plug (19).
e. Remove oiling funnel (25).

3-10. REMOVAL OF T5 WC CASE COVER AND
DISASSEMBLY OF SHIFT FORKS. With

transmission assembly upright, proceed as follows
(see figure 3-4):

a. Remove bolts (26 and 27).
b. If necessary, use suitable knife to break sealant

bond between case cover (38) and transmission
case (117). Move case cover and attached parts
toward drain plug side of transmission

approximately one inch, then lift straight up.
c. Dive out pin (28).
d. Slide out shifter shaft (29), freeing shift forks (30

and 31), selector arm assembly (33), interlock

plate (34) and selector plates (35) from case

cover (38).
e. Remove inserts (32) from shift forks (30 and 31).
f. Remove o-ring (36) from case cover (38) but not

plug (37).

Figure 3-3. T5 WC Extension or Adapter

3-4

Figure 3-4. TT5 W C Case C over

3-111. REMOVAL OF T5 WC 5-R SHIFT LEVER (see

figure 3-5).
a. From inside transmission assembly, remove

retaining ring (39).

b. From outside transmission, remove pivot pin

(40) and back-up switch (41).

c. Work 5-R shift lever (42) out of engagement and

lift out top of transmission case (117).

3-12. REMOVAL OF T5 WC 5TH SYNCHRONIZER
SHIFT FORK AND GEAR. At rear of transmission

case (117), remove parts as follows (see figure 3-6):
a. Remove snap ring (43) and 5th synchronizer

retainer (44).

b. Simultaneously pull 5th synchronizer assembly

(45) and 5th shift fork (51) with attached shift rail
assembly (53),

c. To separate 5th shift fork (51) and shift rail

assembly (53), drive out roll pin (50). Remove
inserts (52) from fork.

Figure 3-5. T5 WC 5-R Shift Lever

3-5

Figure 3-6. T5 WC 5th Synchronizer

Shift Fork and Gear

d. Refer to paragraph 3-20 for disassembly of 5th

synchronizer assembly.

e. Remove blocking ring (54) and 5th speed drive

gear (55) from transmission.

3-13. REMOVAL OF T5 WC SPEEDOMETER
GEAR. On models so equipped, remove

speedometer gear as follows: (see figure 3-7):
a. Remove one snap ring (56) from output shaft

(101).

b. Disengage clip (58) and remove speedometer

gear (57) and clip.

Figure 3-7. T5 WC Speedometer Gear

3-6

3-14. REMOVAL OF T5 WC INPUT SHAFT.

Make alignment mark on input bearing retainer
(60) and transmission case (117) and proceed as
follows (see figure 3-8):
a. Remove bolts (59).
b. If necessary, use suitable knife to break

sealant bond between input bearing retainer
(60) and transmission case (117). Pull
bearing retainer straight out.

c. Use suitable puller to remove oil seal (61)

from input bearing retainer (60).

d. Remove shim(s) (62) and bearing cup (63).

Figure 3-8. T5 WC Input Shaft

e. Rotate input shaft (65) to align flat on its clutch tooth

ring with countershaft (116) and remove from
transmission.

f. If necessary, remove bearing cone (64) from input

shaft (65) using suitable puller.

g. Remove pilot bearing between input shaft (65) and

output shaft (101) as follow, depending on bearing
type:

1. Individual Bearing Rollers. Remove 15
bearing rollers (66A) and spacer (67).

2. Roller Bearing Assembly. Remove bearing
assembly (66ª).

h. remove thrust bearing (68) and thrust race (69)

from end of output shaft (101).

3-15. REMOVAL OF T5 WC OUTPUT SHAFT GROUP.

Remove output shaft group from transmission as
follows (see figure 3-9):

a. Remove one snap ring (56) and 5th driven gear

(70).

b. Push output shaft group (120) rearward to force

bearing cup (71) out of transmission case (117).
Remove bearing cup.

c. Tilt front end of output shaft group (120) up and

remove through top of case.

Figure 3-9. Removal of T5 WC Output Shaft Group

3-7

3-16. DISASSEMBLY OF T5 WC OUTPUT SHAFT
GROUP. After removal from transmission,

disassemble output shaft group as follows (see
figure 3-10):
a. Use suitable puller behind 1 st speed gear (73)

to pull gear and bearing cone (72).

b. Remove 1st speed gear bearing as follows

according to type:

1. One Double-Row Bearing. Remove
bearing (75A).

2. Two Separate Bearings. Remove two
bearings (75B) and spacer (75C).

a. Remove sleeve (76).

Figure 3-10. Disassembly of T5 WC Output Shaft Group

d. At other end of output shaft group, use suitable

puller behind 3rd speed gear (83) to start parts
off output shaft assembly (91). Remove two
blocking rings (77), 3rd-4th synchronizer
assembly (78) 3rd speed gear (83),bearing (84)
and spacer (85).

e. Refer to paragraph 3-20 for disassembly or 3rd-

4th synchronizer assembly.

f. Remove snap ring (86), thrust washer (87), 2nd

speed gear (88) bearing (89) and spacer (90).

g. Refer to paragraph 3-16 for disassembly of

output shaft assembly (91).

3-8

3-17. DISASSEMBLY OF T5 WC OUTPUT SHAFT
ASSEMBLY (see figure 3-11):

a. Remove retaining ring (92) and thrust washer

(93).

b. From each end of shaft and hub assembly (101),

remove inner cone (94), outer cone race (95)
and 1-2 blocking ring (96).

c. Mark reverse sliding gear (98) and hub on shaft

and hub assembly (101) so that clutch teeth can
be assembled exactly as they were originally.

d. Unhook and remove springs (97). Slide reverse

sliding gear (98) from hub on shaft and hub

assembly (101). Freeing inserts (99).
e. Remove pin (100).
f. Do not attempt to disassemble shaft and hub

assembly (101).

Figure 3-11. T5 WC Output Shaft Assembly

3-18. REMOVAL OF T5 WC REVERSE FORK
AND IDLER GEAR (see figure 3-12).

a. Unhook and remove spring (102) and fork pin

and roller assembly (103).

b. Bend down tabs on rear retainer (105) and

remove bolts (104) and retainer. Remove
shim(s) (106).

c. Drive out roll pin (107) holding reverse idler

shaft (108) in transmission case (117).

d. Push reverse idler shaft (108) out rear of

transmission case (117).

e. Remove roll pin (107), reverse idler gear

assembly (109) and o-ring (110) from
transmission case (117).

Figure 3-12. T5 WC Reverse Fork and Idler Gear

3-9

3-19. REMOVAL OF T5 WC COUNTERSHAFT
GEAR (see figure 3-13):

a. Push countershaft gear (116) rearward to force

bearing cup (11) out of transmission case (117).

b. Tilt from end of countershaft gear (116) up and

remove from top of transmission case (117).

c. Push bearing cup assembly (112) out of

transmission case (117) and remove o-ring (113)
from bearing cup (114).

d. Use suitable puller to remove bearing cones

(115) from countershaft gear (116) if necessary.

3-20. DISASSEMBLY OF T5 WC 5TH SYNCHRONIZER
ASSEMBLY. Mark synchronizer sleeve (47) and hub

(49) so that clutch teeth and faces can be assembled
exactly as they were originally. Sleeve and hub are a
matched set, selected at manufacture. Disassemble
as follows (see figure 3-13):
a. Unhook and remove springs (46).
b. Slide sleeve (47) from hub (49), freeing inserts

(48).

Figure 3-13. T5 WC Countershaft Gear

3-10

3-21- DISASSEMBLY OF T5 WC 3RD-4TH
SYNCHRONIZER ASSEMBLY. Mark synchronizer

sleeve (80) and hub (82) so that clutch teeth and
faces can be assembled exactly as they were
originally. Sleeve and hub are a matched set,
selected at manufacture. Disassemble as follows
(see figure 3-14):
a. Unhook and remove spring (79).
b. Slide sleeve (80) from hub (82), freeing inserts

(81).

Figure 3-14. T5 WC 5th Synchronizer Assembly

Figure 3-15. T5 WC 3rd-4th Synchronizer

Assembly

Section 4

T5 STD Disassembly

4-1. GENERAL INFORMATION

4-2. This section provides disassembly instructions
for the T5 STD transmission. The transmission
class can be identified by the last three digits of the
transmission part number. STD units are listed in
Table 4-1. If the number for the transmission to be
disassembled is not listed in Table 4-1, refer to
Section 3, T5 WC Disassembly.

4-3. During disassembly, refer to the illustrations
provided with the text. In addition, an exploded
view of the complete assembly can be seen on
figure 5-2 in Section 5, Cleaning, Inspection,
Repair or Replacement.

4-4. This section provides instructions for complete
disassembly of the T5 STD transmission as would
be the case for overhaul. If the transmission is not
due for overhaul, and repair affecting specific parts
is required, disassemble only to the extent
necessary to gain access to these parts. Parts
removed from the transmission as subassemblies
or groups need not be disassembled for repair
unless they contain the affected parts. Total
disassembly is recommended to ensure that all
parts are absolutely clean.

4-5. REMOVAL AND INSTALLATION OF
TRANSMISSION. Refer to paragraphs 2-10 and

2-21.

4-6. T5 STD TRANSMISSION DISASSEMBLY
PROCEDURES.

4-7. REMOVAL OF T5 STD CONTROL LEVER
AND HOUSING ASSEMBLY AND EXTERNAL
COMPONENTS. Cleans transmission exterior,

support on suitable holding fixture and proceed as
follows (see figure 4-1):

a. Remove fill and drain plugs (1) and drain all fluid

from transmission.

b. Shift transmission into neutral at 3-4 position.

CAUTION

Failure to shift transmission into neutral at 3-4
position before removing control lever and housing
assembly may result in driving roll pin (9, figure 4-2)
into detent guide plate (18) when pin is removed
(paragraph 4-8).

c. Remove screws (2).
d. If necessary, use suitable knife to break sealant

bond between control lever and housing
assembly (3A or 3B) and extension (11A) or
adapter (11B). Remove control lever and
housing assembly. Remove boot (4) only if
replacement is required.

e. Remove vent and o-ring assembly (5A) or

breather (5B).

f. If used, remove neutral switch (6), pin(7) and

wire retainer (8).

001
002

004 thru 008

010
012

013
015 thru 018
026 thru 028
032 thru 035

042

043
047 thru 049

051

Table 4-1. T5 STD Transmissions

(Last Three Digits of Parts Number: 1352-000-XXX)

052

054 thru 056

058
059
061

062
065 thru 068
070 thru 072
074 thru 078

080

081
083 thru 086

102

4-1

107
108
110
136
145
146
151
156
157
164
166
170

181 thru 183

185
187

189 thru 193

201
206
208
211
216
234
239
245
250
252
259

Figure 4-1. T5 STD Control Lever Housing & External Components

4-2