Transmison S10

1991 Chevrolet S10 Pickup
MANUAL TRANS OVERHAUL - BORG-WARNER T5 5-SPEED MANUAL TRANSMISSIONS Borg-Warner T5 5-Speed
MANUAL TRANS OVERHAUL - BORG-WARNER T5 5-SPEED
MANUAL TRANSMISSIONS Borg-Warner T5 5-Speed
APPLICATIONS
TRANSMISSION APPLICATION
Vehicle Application Transmission Model
American Motors Corp.
1983 Concord T5
1983-87 Eagle T5
1983 Spirit T5
Ford Motor Corp.
1984-86 Mercury Capri T50D
1984-86 Mercury Cougar T50D
1987-89 Merkur Scorpio T50D
1985-89 Merkur XR4Ti T50D
1983-94 Mustang T50D
1983-88 Thunderbird T50D
General Motors Corp.
Chevette & 1000 (1983-87, 1.6 Liter) MB4
Camaro & Firebird
1983-92 (5.0 Liter) MK6
1985-89 (2.8 Liter) MB1
1985-92 (5.0 Liter) M39
1990-92 (3.1 Liter) MB1
1993-94 (3.4 Liter) M49
S & T Series Trucks
1984-85 S10 Blazer & Pickup MB1
1985 S15 Jimmy & Pickup MB1
1989-90 S15 Pickup MW1
1989-94 S10 Pickup MW1
1991-94 Sonoma MW1
Jeep Corp.
1983-84 Cherokee T5
1983-83 CJ5 T5
1983-86 CJ7 T5
1983-83 Pickup T5
1983-85 Scrambler T5
1983-84 Wagoneer T5
IDENTIFICATION
jueves, 29 de agosto de 2019 10:45:42
10:45:38 p. m. Page 1 © 2011 Mitchell Repair Information Company, LLC.
Identification code is located on extension bolt on left side of transmission. Ford Motor Co. refers to this
transmission as T50D 5-Speed Overdrive, and General Motors refers to this transmission as 77 MM 5-Speed.
DESCRIPTION
The Borg-Warner T5 5 speed, is a constant mesh synchronized transmission. The 5th speed is an overdrive gear.
The T5 has an aluminum case with metric fasteners.
LUBRICATION & ADJUSTMENTS

See appropriate TRANSMISSION SERVICING - M/T article in MANUAL TRANS SERVICE.
TROUBLE SHOOTING
See TROUBLE SHOOTING - BASIC PROCEDURES article in GENERAL TROUBLE SHOOTING.
ON-VEHICLE SERVICE
GEARSHIFT LEVER
Removal & Installation
1. Remove 4 bolts attaching shift boot to floor pan. Remove shift lever-to-transmission bolts. To install,
reverse removal procedure.
2. On Ford models, shift lever bolts must only be installed from left side of shift lever. On General Motors
models, the upper and lower shift levers are bonded together. Separation of the levers will damage shifter
and will require replacement of shifter assembly.
EXTENSION HOUSING BUSHING & OIL SEAL
Removal & Installation
1. Remove propeller shaft. Pry out oil seal with screwdriver. Insert bushing puller into extension housing
until it grips front side of bushing. Turn clockwise until bushing is free.
2. Drive NEW bushing into extension housing. Install new oil seal, and install propeller shaft.
REMOVAL & INSTALLATION

See appropriate TRANSMISSION REMOVAL & INSTALLATION - M/T article in MANUAL TRANS
SERVICE.
TRANSMISSION DISASSEMBLY
CAUTION: If replacing bolts, use only those of same size and length as originals.
jueves, 29 de agosto de 2019 10:45:38 p. m. Page 2 © 2011 Mitchell Repair Information Company, LLC.
NOTE: See Fig. 4 for exploded view of transmission.
1. Drain lubricant and position shift lever in Neutral. Remove turret cover attaching bolts. Using a pry bar,
break seal between turret cover and extension housing. Remove turret cover.
2. Remove back-up light switch and external components. DO NOT remove offset lever while extension
housing is bolted in place.
3. Using a pin punch and hammer, remove roll pin attaching offset lever to shift rail. Remove damper
sleeve. Remove extension housing-to-transmission bolts, and remove housing and offset lever as an
assembly by sliding rearward.
4. On AMC and Jeep models remove plastic funnel, thrust bearing race and thrust bearing from rear of
countershaft, found on end of countershaft or inside adapter housing. On Ford models, remove offset
lever, roll pin detent spring and detent ball from extension housing detent plate.
5. Remove offset lever from assembly. Remove roll pin, detent spring and detent ball from extension
housing detent plate.
6. Remove bolts attaching cover assembly to transmission. Remove cover. Remove "C" clip retaining
5th/reverse shift lever. See Fig. 1 . Remove shift lever pivot pin.
Fig. 1: Removing 5th/Reverse Shift Lever "C" Clip

Courtesy of FORD MOTOR CO.
7. Remove 5th gear synchronizer snap ring. Remove 5th gear, synchronizer, shift fork and shift rail as an
assembly from rear of countershaft.
8. Press downward on speedometer gear retaining clip and slide gear off shaft. Remove retaining clip. Mark
front bearing retainer for assembly reference. Remove front bearing retainer bolts. Remove front bearing
retainer.
9. Rotate input shaft until flat surface on main drive gear faces countershaft, remove input shaft from
transmission. Remove 4th gear blocking ring from 3rd/4th synchronizer. Remove output shaft rear
bearing race. Tilt output shaft upward and remove through top of transmission case. See Fig. 2 .
Fig. 2: Removing & Installing Output Shaft Assembly

10. Remove 5th/reverse shift lever, reverse shift fork and return spring. See Fig. 3 . Remove roll pin from
front end of reverse idler shaft. Remove reverse idler shaft and gear by sliding out back of transmission
case.
11. Flatten tabs on countershaft retaining bolts. Remove countershaft bolts, retainer and shim. Remove rear
countershaft race. It may be necessary to work shaft back and forth to remove race.
12. Using puller (T81P-1104-C1) and puller clamp (D84L-1123-A) pull countershaft bearing. Slide back and
tilt shaft upward to remove from case.
Fig. 3: Removing & Installing Reverse Shift Lever, Fork & Spring
Fig. 4: Exploded View of Borg-Warner T5 5-Speed Overdrive Transmission

COMPONENT DISASSEMBLY & REASSEMBLY
OUTPUT SHAFT
Disassembly
1. Scribe alignment mark on 3rd/4th synchronizer hub and sleeve for reassembly reference. Using puller (J-
22912) and universal press plate (D79L-4621-A), remove 3rd/4th synchronizer, 3rd blocking ring and 3rd
gear as an assembly. See Fig. 5 . Remove needle bearing and spacer from output shaft.
Fig. 5: Disassembling Output Shaft

2. Remove snap ring that retains 5th gear on shaft. Using puller and universal press plate, remove 5th gear.
Slide rear bearing off mainshaft.
3. Remove 1st gear, remove needle bearing and sleeve. Remove 1st gear roll pin (using diagonal cutters)and
1st gear synchronizer ring assembly. Remove 2nd gear snap ring and thrust washer. Remove 2nd gear
from output shaft. Remove needle bearing and spacer from output shaft.
4. Remove spiral snap ring and thrust washer from output shaft. Remove 2nd gear synchronizer ring
assembly. Remove 1st/2nd synchronizer from output shaft. See Fig. 4 .
5. Remove detent ball and spring from hub. DO NOT attempt to remove 1st/2nd/reverse hub from output
shaft. Hub and shaft are machined as a machined set.
Reassembly
1. Coat output shaft and gear bores with transmission oil. Install 1st/2nd gear synchronizer assembly and
2nd gear synchronizer ring assembly. Align slots in synchronizer ring with tabs in 1st/2nd gear
synchronizer assembly. For synchronizer disassembly and assembly see SYNCHRONIZERS .
NOTE: If any output shaft gear is replaced, the countershaft gear must also be
replaced to maintain proper gear mesh and avoid noisy operation.
2. Install tabbed thrust washer and 2nd gear retaining snap ring on output shaft. Ensure washer tab is
properly seated in output shaft notch.
3. Install 2nd gear needle bearing and spacer. Install 2nd gear and align slot with tabs on synchronizer ring
assembly. See Fig. 6 . Install 2nd gear snap ring and thrust washer.
Fig. 6: Installing & Aligning 2nd Gear

4. Install 1st gear synchronizer ring assembly. Align slot in 1st gear synchronizer ring with tab on 1st/2nd
gear synchronizer. Install roll pin in output shaft. Install needle bearing and sleeve, aligning notch in
sleeve with roll pin. Slide rear bearing on output shaft.

5. Install 1st gear, aligning slot with tab on 1st gear synchronizer ring assembly. Install rear output shaft
bearing with taper facing rear of shaft.
6. Using installer (J-22912) and arbor press, install 5th gear on output shaft. Install 5th gear snap ring. Install
needle bearing and spacer assembly onto output shaft.
7. Using press install 3rd/4th gear synchronizer, 3rd blocking ring and 3rd gear as an assembly on output
shaft. Hub offset must face forward. Hold 3rd gear against synchronizer to maintain blocking ring
alignment.
SYNCHRONIZERS
Disassembly
Before disassembling, scribe alignment marks on sleeve and hub for assembly reference. Remove insert retainer
(5th gear synchronizer only). See Fig. 7 . Remove retaining springs and inserts. On 1st/2nd synchronizer, sleeve
should be removed to prevent loss of detent ball and spring.
NOTE: The 1st/2nd gear synchronizer is available only as an assembly with the output
shaft. DO NOT attempt to separate hub from shaft.
Reassembly
Assemble inserts and synchronizer retaining springs onto sleeve and hub. Retaining springs engage same insert
but rotate in opposite directions. Install insert retainer on 5th gear synchronizer and ensure retainer tabs are
positioned over synchronizer inserts. See Fig. 4 . On 1st/2nd gear synchronizer, install detent ball and spring
into hub on output shaft, and assemble retaining springs, inserts and sleeve onto hub.
Fig. 7: Exploded View of Synchronizer Assemblies

Courtesy of GENERAL MOTORS CORP.
SHIFT COVER ASSEMBLY
Disassembly
1. Place selector arm plates and shift rail in Neutral. Rotate shift rail counterclockwise until selector arm
disengages from selector arm plates and selector arm roll pin is accessible.
2. Pull shift rail rearward until selector arm contacts 1st/2nd shift fork. Using a punch, remove selector arm
roll pin. See Fig. 8 . Remove shift rail.
Fig. 8: Removing Shift Rail Retaining Roll Pin

3. Remove shift forks, selector arm plates, selector arm, roll pin and interlock plate. Using a screwdriver,
remove shift rail oil seal and "O" ring. Using a hammer and punch, remove shift rail plug.
4. Remove nylon inserts and selector arm plates from shift forks. Note position of inserts and plates for
reassembly reference.
Reassembly
1. Install nylon inserts and selector arm plates in shift forks. Apply sealer to edge of shift rail plug and
install plug. Coat shift rail and bore with petroleum jelly. Install shift rail in cover with end of rail flush
with inside edge of cover.
2. Position 1st/2nd shift fork in cover with fork offset facing rear of cover. Push shift rail through fork.
Position selector arm and "C" shaped interlock plate in cover, and insert shift rail. Widest part of interlock
plate must face away from cover, and selector arm roll pin hole must face downward and toward rear of
cover.
3. Position 3rd/4th shift fork in cover with fork offset facing rear of cover. Fork selector arm plate must be
positioned under 1st/2nd shift fork selector arm plate. Insert shift rail through 3rd/4th shift fork and into
shift rail bore in cover. Rotate shift rail until selector arm plate faces away from cover. See Fig. 4 .
4. Align roll pin holes in selector arm and shift rail. Install roll pin. Failure to install roll pin below surface
may cause interference during shifts. Install "O" ring in groove of shift rail oil seal. Install shift rail oil
seal in cover.
INPUT SHAFT BEARING
Disassembly & Reassembly
Using a press and Universal Press Plate (D79L-4621-A), remove input shaft bearing. To install, use a press and
a capped length of pipe to install bearing.
INPUT SHAFT BEARING RETAINER SEAL
Disassembly & Reassembly
Remove bearing race and end play shim. Using a screwdriver, carefully pry out seal from bearing retainer.
Using Bearing Retainer Seal Installer (T77F-4220-A), install new seal. Install end play shim and bearing race.
NOTE: If seal is replaced as part of a transmission overhaul, DO NOT install end play
shim.
CLEANING & INSPECTION

1. Wash all parts in solvent. Dry all parts except bearings with compressed air. Allow bearings to air dry or
wipe dry with a clean shop cloth. Clean needle, thrust and roller bearings.
2. Inspect transmission case, cover and extension housing. Replace transmission case, cover or extension
housing if there are cracks in bores, sides, bosses or bolt holes. Replace case if there are stripped bolt
holes, nicks, burrs, or rough surfaces in shaft bores or on gasket surfaces.
3. Inspect gear train and shift mechanism. Replace any parts exhibiting wear, chips, galling, distortion or
bending. Check for worn bearings and bores. Check for weak snap rings and stripped offset lever.
TRANSMISSION REASSEMBLY
1. Coat countershaft front bearing outer cage with Loctite 601. Using a press, install countershaft front
bearing flush with case.
CAUTION: Failure to properly support countershaft during bearing installation

can result in permanent damage to transmission case.
2. Place transmission case on end, and install countershaft in front bearing. Support countershaft with 2
pieces of 1/4" bar stock under front gear. Using bearing installer and press, install countershaft rear
bearing onto countershaft. Install rear race onto countershaft.
3. Install countershaft retainer without shims to transmission case. Tighten to specification. Refer to the
appropriate TORQUE SPECIFICATIONS . Measure end play using dial indicator. Remove retainer
and install necessary shims. Ensure end play is .001-.005" (.025-.127 mm).
4. Place reverse idler gear in case with shift lever groove facing case. Install reverse idler shaft from rear of
case. Install retaining roll pin. Place reverse shift fork and 5th/reverse shift lever in case. See Fig. 3 .
5. Install assembled output shaft in transmission case. Coat input shaft roller bearings, thrust bearing and
race with petroleum jelly, and install inside input shaft. Install blocking ring, aligning notches with inserts
in 3rd/4th synchronizer.
6. Install input shaft, aligning flat on synchronizer with countershaft. Install front bearing race in bearing
retainer without shims. Temporarily install bearing retainer. Tighten bolts to specification.
7. Install output shaft rear bearing race. Tap into place with plastic-tip hammer, if necessary. Install 5th
speed gear on countershaft. Slide shift rail, 5th gear shift fork assembly into case. Align shift fork and
slide rail through fork. Position lever return spring in case, and slide shift rail the remaining distance
through spring.
NOTE: Long end of spring must face rear of case.
8. Install blocking ring and 5th gear synchronizer in 5th gear shift fork. Slide fork rail assembly onto
countershaft. Install 5th gear synchronizer retainer and snap ring. Connect lever return spring to case.
9. Apply Teflon sealer to pivot bolt and install. Tighten to specification. See appropriate TORQUE
SPECIFICATIONS table. Ensure reverse shift fork pin and 5th gear shift rail pin are engaged with shift
lever. Install "C" clip on pivot bolt. Install speedometer gear and retaining clip on rear of output shaft.
10. Apply 1/8" bead sealant to assembled shift cover. Lower cover until shift forks engage synchronizers.
Continue lowering cover, and position to engage 5th/reverse shift lever. Ensure all synchronizers and
forks are in Neutral position. Install bolts and tighten to specification.
11. Apply 1/8" bead sealant to extension housing and lubrication funnel. Install funnel to extension housing.
Install detent spring into offset lever and place steel ball in neutral guide plate detent. See Fig. 9 . Position
offset lever in extension housing with spring over detent ball.
Fig. 9: Locating Offset Lever, Ball & Spring

12. Slide offset lever and extension housing to transmission case. Apply pressure to steel ball with detent
spring and offset lever, pushing lever and housing into position. See Fig. 9 . Install and tighten housing
bolts to specification.
13. Align roll pin hole in shift rail and offset lever, and install pin. Install damper sleeve in offset lever. Turn
transmission case on end and mount dial indicator on extension housing with indicator pointer on end of
output shaft. Rotate clutch and output shaft and zero dial indicator. Pull upward on output shaft and read
end play on dial indicator. See Fig. 10 .
Fig. 10: Measuring Output Shaft End Play

14. Select a shim pack equal to measurement on dial indicator. Remove front bearing retainer and race. Add
shims to cap and install bearing race in cap. Apply silicone sealant to front bearing retainer and install on
transmission case. Tighten to specification. Ensure no end play exists.
CAUTION: Ideal end play specification is zero. Acceptable tolerance is up

to .002" (.051 mm). DO NOT overload bearings with excessive shims.
15. Apply bead of silicone sealant to turret cover. Install cover on extension housing and tighten bolts to
specification. Coat back-up light switch threads with silicone sealant, and install switch.
TORQUE SPECIFICATIONS
AMERICAN MOTORS
TORQUE SPECIFICATIONS (AMERICAN MOTORS EAGLE (1)

Application Ft. Lbs. (N.m)
Bell Housing-to-Engine
Top Bolts 27 (37)
Bottom Bolts 43 (58)
Transmission-to-Bell Housing 55 (75)
Rear Crossmember Studs 30 (41)
Support-to-Crossmember 18 (24)
(1) Information for Concord and Spirit not available.
FORD MOTOR CO.
TORQUE SPECIFICATIONS (FORD MOTOR CO.)

Back-Up Light Switch
1991 12-18 (16-24)
1992 20-35 (27-47)
Bearing Retainer Bolt 11-20 (15-27)
Cluster Gear Rear Bearing Retainer Ring 11-15 (15-20)
Drain Plug 15-22 (20-30)
Extension Housing Bolts 30-35 (41-47)
Neutral Sensing Switch
1991 12-18 (16-24)
1992 20-35 (27-47)
Shift Lever-To-Transmission Bolt 23-32 (31-43)
Top Gear Sensing Switch 12-18 (16-24)
Transmission Support Nuts 36-50 (49-68)
Transmission-To-Flywheel Housing Bolts 45-65 (61-88)
Turret Cover Bolts 11-15 (15-20)
INCH Lbs. (N.m)
Shift Boot-To-Floor Pan 36-84 (4-9)
Shift Cover Bolts 72-132 (8-15)
Speedometer Cable Retaining Bolt
1991 36-54 (4-6)
1992 54-115 (6-13)
GENERAL MOTORS
TORQUE SPECIFICATIONS (GENERAL MOTORS)

Back-Up Light Switch 12-18 (16-24)
Countershaft Retainer-To-Case 15 (20)
Drain & Fill Plug 20 (27)
Extension Housing-To-Case Bolts 25 (34)
Front Bearing Retainer-To-Case 15 (20)
Reverse Pivot Bolt 20 (27)
Transmission Cover-To-Case Bolt 10 (14)
Transmission Support Bolts 40 (54)
Transmission Support Nuts 35 (47)
Transmission-To-Engine Bolts 55 (75)
INCH Lbs. (N.m)
Shift Boot-To-Floor Pan 53 (6)
Speed Sensor Retainer Bolt 89 (10)
JEEP
TORQUE SPECIFICATIONS (JEEP)

Transmission-to-Clutch Housing 55 (75)
Transmission Cover Bolts 55-65 (75-88)
Housing-to-Transmission Case 40-45 (54-61)
Crossmember Attaching Bolts 34-40 (47-54)
Filler Plug 13-15 (18-20)

Transmison S10

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1991 Chevrolet S10 Pickup

MANUAL TRANS OVERHAUL - BORG-WARNER T5 5-SPEED MANUAL TRANSMISSIONS Borg-Warner T5 5-Speed

MANUAL TRANS OVERHAUL - BORG-WARNER T5 5-SPEED

MANUAL TRANSMISSIONS Borg-Warner T5 5-Speed

LUBRICATION & ADJUSTMENTS

Removal & Installation

EXTENSION HOUSING BUSHING & OIL SEAL

Removal & Installation

REMOVAL & INSTALLATION

NOTE: See Fig. 4 for exploded view of transmission.

Fig. 1: Removing 5th/Reverse Shift Lever "C" Clip

Fig. 2: Removing & Installing Output Shaft Assembly

Fig. 4: Exploded View of Borg-Warner T5 5-Speed Overdrive Transmission

COMPONENT DISASSEMBLY & REASSEMBLY

Fig. 5: Disassembling Output Shaft

Fig. 6: Installing & Aligning 2nd Gear

sleeve with roll pin. Slide rear bearing on output shaft.

Fig. 7: Exploded View of Synchronizer Assemblies

SHIFT COVER ASSEMBLY

Fig. 8: Removing Shift Rail Retaining Roll Pin

INPUT SHAFT BEARING

Disassembly & Reassembly

INPUT SHAFT BEARING RETAINER SEAL

Disassembly & Reassembly

CLEANING & INSPECTION

CAUTION: Failure to properly support countershaft during bearing installation

NOTE: Long end of spring must face rear of case.

Fig. 9: Locating Offset Lever, Ball & Spring

Fig. 10: Measuring Output Shaft End Play

CAUTION: Ideal end play specification is zero. Acceptable tolerance is up

TORQUE SPECIFICATIONS (AMERICAN MOTORS EAGLE (1)

FORD MOTOR CO.

TORQUE SPECIFICATIONS (FORD MOTOR CO.)

1992 54-115 (6-13)

TORQUE SPECIFICATIONS (GENERAL MOTORS)

TORQUE SPECIFICATIONS (JEEP)

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