ZF-6 Caja Sincronica Z6 Triton

308-03-1 Manual Transaxle/Transmission — ZF 6-Speed 308-03-1
SPECIFICATIONS
General Specifications (Continued)
Material
Item Specification
Item Specification Fill Capacity
Top roller bearing outer 150°C (302°F)
Gasket Maker WSK-M2G348-A5 — race
TA-16
Output ball bearing 150°C (302°F)
MERCON V MERCON V 5.5L
Automatic (11.6 pt)a Physical Weight
Transmission Fluid Transmission (with fluid) 113 kg (250 lb)
XT-5-QM (or
XT-5-QMC) (US); Preload
CXT-5-LM12 Mainshaft and 0.02-0.09 mm
(Canada) countershaft (0.0007-0.003 in)
Motorcraft Full WSD-M2C200-C 5.5L Synchronizer
Synthetic Manual (11.6 pt)b
Transmission Fluid 1st and 2nd service limit 1.0 mm (0.39 in)
XT-M5-QS 1st and 2nd synchronizer 1.5-1.85 mm
Premium Long-Life ESA-M1C75-B — with new gear and (0.059-0.072 in)
Grease synchronizer ring
XG-1-C or XG-1-K clearance
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(US); CXG-1-C 3rd, 4th, 5th, reverse and 1.0 mm (0.39 in)
(Canada) low service limit
Threadlock and WSK-M2G351-A5 — 3rd, 4th, 5th, reverse and 1.4-1.7 mm
Sealer low with new gear and (0.055-0.066 in)
TA-25 synchronizer ring
Threadlock 262 WSK-M2G351-A6 — clearance
TA-26
a Gas engines Torque Specifications
b Diesel engines
Description Nm lb-ft lb-in
General Specifications
Detent plunger 65 48 —
Item Specification assembly
Transmission Fluid Drain plug 35 26 —
NOTICE: Driveshaft flange bolts a 111 82 —
Use only transmission fluid that is recommended for Driveshaft flange bolts b 102 75 —
this transmission, the use of any other transmission
fluid may result in transmission failure. Dust cover bolts 28 21 —
NOTE: Extension 23 17 —
Approximate dry capacity includes transmission fluid housing-to-case bolts
cooler and transmission fluid cooler tubes. Transmission Fill plug 35 26 —
fluid level procedures in this section should be used to
determine actual transmission fluid requirements and Guide tube bolts 23 17 —
transmission fluid specification. Idler shaft bolt 23 17 —
DO NOT OVERFILL. If it is necessary to add or
change transmission fluid, use only transmission fluid Interlock plate bolts 10 — 89
that is recommended for this transmission. Intermediate 23 17 —
Component Mounting Temperatures housing-to-case bolts
Taper roller bearing inner 150°C (302°F) Power Take-Off (PTO) — — —

race cover plate boltsc
Synchronizer assemblies 150°C (302°F) Mainshaft drag 2-8 — 18-70
Thrust washers 150°C (302°F) Reverse lamp switch 20 — 177
Shaft bushings 150°C (302°F) Shift housing-to-case 23 17 —

bolts
Copyright  2007, Ford Motor Company

Last updated: 8/10/2009 2008 F-250, 350, 450, 550 Super Duty, 7/2007
SPECIFICATIONS (Continued)
Torque Specifications (Continued) Torque Specifications (Continued)
Description Nm lb-ft lb-in Description Nm lb-ft lb-in
Transfer case control 35 26 — Transmission support 70 52 —
lever assembly bolts crossmember bolts and
Transfer case shift 27 20 — nuts
lever bolt Transmission-to-engine 63 46 —
Transmission fluid 27 20 — bolts
cooler tubes Upper gearshift lever 35 26 —
Transmission mount 81 60 — bolt
nuts a Diesel engines.
Transmission mount 75 55 — b Gasoline engines.
studs c Refer to the procedure in this section.
Transmission output 330 244 —
flange locknut
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2008 F-250, 350, 450, 550 Super Duty, 7/2007

DESCRIPTION AND OPERATION

Manual Transmission • 3rd 1.31:1
The S6-650 and the 65-750 transmissions are • 4th 1.00:1
6-speed synchronized units. The ZF 6-speed has the • Overdrive or 5th 0.72:1
following features:
• Reverse 5.23:1
• An integral clutch housing
Transmission Identification
• An aluminum main case, extension housing and
intermediate housing All ZF transmissions are identified by the model
and serial number. This information is on the
• The mainshaft has 2 tapered roller bearings. transmission identification tag and affixed to the
Mainshaft end play is controlled by a selective transmission case. Do not remove or destroy the
shim located under the bearing cup transmission identification tag.
• The countershaft has 2 tapered roller bearings.
The countershaft end play is controlled by a Lubrication
selective shim located under the bearing cup NOTICE: Additives and friction modifiers are
• The countershaft is serviced as an assembly not recommended for use in ZF transmissions or
damage may occur.
• Synchronized in all gears
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ZF transmissions are designed so that the internal
• All gears are helical parts operate in an oil bath circulated by the motion
• All gears, including reverse, turn on needle roller of the gears and shafts. All parts are amply
bearings lubricated if these procedures are followed:
• Single-piece shift forks with moly-coated pads • Maintain the correct fluid level by inspecting it
• Internal oil pump, driven by the countershaft, to regularly.
supply transmission fluid to an external cooler • Change the fluid regularly. Refer to the Owner’s
• Provisions for mounting a Power Take-Off (PTO) Literature for the recommended intervals.
unit • Use the manual transmission fluid specified in the
• A reverse idler gear that does not need to be Specifications.
removed during disassembly High operating temperatures increase the lubricant’s
• The mainshaft and countershaft are assembled rate of oxidation and shorten its effective life. When
under preload. If the ZF transmission is the average operating temperature is high, the
disassembled, a preload measurement must be transmission may require more frequent fluid
taken changes or external cooling. External oil coolers
The S6-650 and the 65-750 have 6 forward speeds are used to reduce high operating temperatures. The
that feature a LOW gear for take-off under heavy following conditions in any combination can cause
loads and a OVERDRIVE gear for highway driving high operating temperatures:
conditions. The gear ratios are as follows: • Operating consistently at slow speeds
• Low 5.79:1 • High ambient temperatures
• 1st 3.30:1 • Restricted air flow around the transmission
• 2nd 2.10:1 • Exhaust system too close to the transmission

DIAGNOSIS AND TESTING

Manual Transmission
Refer to Section 308-00.
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GENERAL PROCEDURES
Transmission Draining and Filling
Special Tool(s)
Oil Suction Gun
303-D104 (D94T-9000-A) or
equivalent
Material
Item Specification 3. Apply threadlock and sealer and install the
MERCON V Automatic MERCON V drain plug.
Transmission Fluid • Tighten to 35 Nm (26 lb-ft).
XT-5-QM (or XT-5-QMC)
(US); CXT-5-LM12
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(Canada) 4. NOTE: Prior to removal, clean the area around
Motorcraft Full WSD-M2C200-C the fill plug.
Synthetic Manual Remove the fill plug.
Transmission Fluid
XT-M5-QS 5. NOTE: Do not overfill the transmission. This
Threadlock and Sealer WSK-M2G351-A5 will cause transmission fluid to be forced out of
TA-25 the case.
NOTE: Transmission fluid usage: Using an Oil Suction Gun, fill the transmission
with the recommended fluid. For additional
• Gas engines use MERCON V Fluid. fluid capacity information, refer to
• Diesel engines use Motorcraft Full Synthetic Specifications in this section.
Fluid.
1. With the vehicle in NEUTRAL, position it on a

hoist. For additional information, refer to
Section 100-02.
2. NOTE: Drain the transmission while the

transmission fluid is warm.
Position a drain pan under the transmission and
remove the drain plug.
• Drain the transmission fluid.
6. Apply threadlock and sealer and install the fill

plug.
• Tighten to 35 Nm (26 lb-ft).

IN-VEHICLE REPAIR
Output Shaft Seal Removal
Special Tool(s) All vehicles
Holding Fixture, Drive Pinion

Flange 1. With the vehicle in NEUTRAL, position it on a
205-126 (T78P-4851-A) hoist. For additional information, refer to
Section 100-02.
2. NOTE: Index-mark the driveshaft to the flange.

Remove and discard the driveshaft bolts.
Installer, Output Shaft Oil Seal Disconnect the rear driveshaft from the
(4x2) transmission and position it aside. For other
308-382 driveshaft configurations, refer to Section
205-01.
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Installer, Output Shaft Oil Seal
(4x4)
308-383
Remover, Input Shaft Oil Seal

308-375
Four-Wheel Drive (4WD) vehicles
3. Remove the transfer case. For additional

information, refer to Section 308-07B.
Slide Hammer
100-001 (T50T-100-A)
4. Using the Input Shaft Oil Seal Remover and the
Slide Hammer, remove and discard the output
oil seal.
Socket, Mainshaft Locknut (36

mm)
308-127 (T87T-7025-AH)
Material
Item Specification
Threadlock 262 WSK-M2G351-A6
TA-26

IN-VEHICLE REPAIR (Continued)
Rear Wheel Drive (RWD) vehicles 2. Install the transfer case. For additional
information, refer to Section 308-07B.
5. Using the Drive Pinion Flange Holding Fixture
and the Mainshaft Locknut (36-mm) Socket, RWD vehicles
remove the transmission flange.
3. Using the Output Shaft Oil Seal Installer (4x2),
install a new output oil seal.
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6. Remove and discard the output oil seal.
4. Apply threadlock to the threads of the

transmission output flange locknut. Using the
Drive Pinion Flange Holding Fixture with the
Mainshaft Locknut Socket, install the
transmission flange and transmission output
flange locknut.
Installation
4WD vehicles
1. Using the Output Shaft Oil Seal Installer (4x4),

install a new output oil seal.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

All vehicles 6. For vehicles equipped with a gasoline engine,
install new driveshaft flange bolts.
5. NOTE: Make sure the index marks made • Tighten to 102 Nm (75 lb-ft).
during removal are aligned.
Connect the rear driveshaft. 7. For vehicles equipped with a diesel engine,
install new driveshaft flange bolts.
8. For other driveshaft configurations, refer to

Section 205-01.
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2008 F-250, 350, 450, 550 Super Duty, 7/2007

IN-VEHICLE REPAIR
Gearshift Lever and Boot
Material
Item Specification
Gasket Maker WSK-M2G348-A5
TA-16
Threadlock and Sealer WSK-M2G351-A5
TA-25
Removal
1. Remove the shift lever boot and position it

aside. 4. Remove the 4 lower gearshift lever bolts, then
remove the lower gearshift lever and shift
housing.
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2. Loosen the upper gear shift lever bolt, then
remove the upper gearshift lever.
5. Separate the lower shift lever and gearshift
lever blocks from the shift housing.
Installation
1. Install the lower gearshift lever and gearshift

lever blocks into the shift housing.
• Install the gearshift lever blocks with the
notches facing downward.
3. Remove the 2 screws and the lower shift lever

boot.

2. NOTE: Do not use a silicone sealing 4. Apply threadlock and sealer to the gearshift
compound or damage to the components can lever bolt, and install the upper gearshift lever.
occur. • Tighten to 35 Nm (26 lb-ft).
NOTE: Do not wait longer than 10 minutes to
tighten the bolts due to the rapid cure time of
the sealant.
Install the shift housing and shift
housing-to-case bolts.
• Apply gasket maker to the sealing surfaces.
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5. Install the shift lever boot.
3. Install the lower shift lever boot and the 2

screws.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

REMOVAL AND INSTALLATION

Transmission — Gasoline Engines
Special Tool(s)
Transmission Jack
014-00942
All vehicles
4. Remove the 4 shift housing bolts and the shift
1. Pull the shift lever boot upward to access the housing.
shift housing.
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Vehicles with a manual shift transfer case
2. Loosen the upper gearshift lever bolt, then
remove the upper gearshift lever. 5. Shift the transfer case into 4H.
6. Remove the 2 screws that attach the bezel and

boot assembly to the floor.

boot.

REMOVAL AND INSTALLATION (Continued)
7. Slide the bezel and boot up the shift lever.
Remove the bolt that attaches the shift lever to
the transfer case control lever assembly, and
remove the shift lever and the bezel and boot
assembly.
All vehicles

Section 100-02.
9. If the transmission is being disassembled, drain

the transmission fluid. 15. Disconnect the fuel tubes from the transmission.
10. Remove the exhaust Y-pipe. For additional

information, refer to Section 309-00.
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11. Remove the starter. For additional information,
refer to Section 303-06A.
12. Remove the skid plate, if equipped.
16. Remove any Power Take-Off (PTO) equipment,

if equipped.
17. Using the Transmission Jack, support the

transmission.
• Securely strap the Transmission Jack to the
transmission.
13. Remove the transfer case, if equipped. For
additional information, refer to Section
308-07B.

Disconnect the rear driveshaft and position it
aside. For other driveshaft configurations, refer
to Section 205-01.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

18. Remove the 4 RH crossmember nuts.
22. Disconnect the wiring harness from the

transmission.
19. Remove the 3 LH crossmember bolts.
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23. Remove the clutch slave cylinder and position it
20. Remove the 2 transmission mount nuts and the aside.
crossmember. • Push the clutch slave cylinder inward, then
rotate counterclockwise 45 degrees to
remove.
21. Disconnect the reverse lamp switch electrical

connector.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

24. Disconnect the transmission fluid cooler tubes. 25. Remove the 2 dust cover bolts.
26. Remove the 7 transmission-to-engine bolts.
27. Remove the transmission.

• Move the transmission rearward until the
input shaft is clear of the clutch, then lower
from the vehicle.
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2008 F-250, 350, 450, 550 Super Duty, 7/2007


Transmission — Diesel Engines
Special Tool(s)
Transmission Jack
014-00942
All vehicles
4. Remove the 4 shift housing bolts and the shift
1. Pull the shift lever boot upward to access the housing.
shift housing.
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2. Loosen the upper gearshift lever bolt, then
remove the upper gearshift lever. 5. Shift the transfer case into 4H.
6. Working under the vehicle, remove the 2 bolts

that attach the shift lever to the transfer case
control lever assembly. Disconnect the
transmission-to-transfer case linkage.

boot.

13. Using the Transmission Jack, support the
transmission.
• Securely strap the Transmission Jack to the
transmission.
14. Remove the 4 RH crossmember nuts.
All vehicles

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Section 100-02.
8. If the transmission is being disassembled, drain

the transmission fluid. 15. Remove the 3 LH crossmember nuts.
9. Remove the skid plate, if equipped.
10. Remove the transfer case, if equipped. For

308-07B.

Disconnect the rear driveshaft and position it
aside. Support the driveshaft. For other
driveshaft configurations, refer to Section
205-01.
16. Disconnect the wire harness from the

crossmember.
17. Remove the 2 transmission mount nuts and the

crossmember.
12. Remove the Power Take-Off (PTO) equipment,

if equipped.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

18. Disconnect the reverse lamp switch electrical 21. Disconnect the transmission fluid cooler tubes.
connector.
22. Remove the 8 transmission-to-engine bolts.

19. Disconnect wiring harness from the
transmission.
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20. Remove the clutch slave cylinder and position it
aside.
• Push the clutch slave cylinder inward, then
rotate counterclockwise 45 degrees to
remove.
23. Remove the transmission.

• Move the transmission rearward until the
input shaft is clear of the clutch, then lower
from the vehicle.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

DISASSEMBLY AND ASSEMBLY

Transmission Special Tool(s)
Remover, Jet Plug
Special Tool(s) 310-005 (T77L-9533-B)
2 or 3 Jaw Puller
205-D027 (D80L-1013-A) or
equivalent
Shaft Protector Set

205-DS004 (D80L-625-A) or
equivalent
Centerplate Legs
308-380

mm)
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308-127 (T87P-7025-AH)
Fixture, Gear Pack
308-381
All vehicles
Gear/Bearing Heater NOTE: For additional information, refer to the

164R-3900 exploded view under the Assembly procedure in this
section.
1. Clean the transmission exterior with solvent and

dry with compressed air.
Holding Fixture, Drive Pinion 2. Remove the clutch release lever and the clutch
Flange release hub and bearing.
205-126 (T78P-4851-A)
Remover/Installer, Front Wheel

Hub
204-069 (T81P-1104-C)
(Continued)

DISASSEMBLY AND ASSEMBLY (Continued)
3. NOTE: For vehicles equipped with gasoline All vehicles
engines, the transmission must be elevated
50-101 mm (1.968-3.976 in) to prevent damage 5. Remove the 19 extension housing bolts.
to the input shaft.
Position the transmission on the floor with the
output flange pointing upward.
6. NOTE: Use a 1/8-in center punch to create a
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pilot hole in the plug before installing the tool.
Using the Jet Plug Remover to make the pilot
hole will damage the tool.
NOTE: Lightly thread in the Jet Plug Remover
so as not to damage the springs.
Using the Jet Plug Remover, remove the detent
plugs and shift detent springs. Discard the
detent plugs.
Rear Wheel Drive (RWD) vehicles
4. Using the Drive Pinion Flange Holding Fixture

and the Mainshaft Locknut (36-mm) Socket,
remove the pinion flange.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

7. Remove the main shift detent.
8. Separate the main shift detent from the detent

plunger.
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• Inspect the detent plunger for wear or
damage. Install a new dent plunger as
necessary.
10. Remove the intermediate housing-to-case bolts.
9. Remove the extension housing from the

intermediate housing.
• Using a soft-faced hammer, tap the
extension housing lightly to break the gasket
seal.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

11. Using a suitable lifting device, a suitable chain
and 2 S-hooks, lift the intermediate housing and
gear assembly out of the main case.
• Place the S-hooks in the intermediate
housing where the 2 bolts were removed.
• Place a protective cover or rag around the
chain. This will make sure the low and
reverse gears are not damaged during
removal.
• Lift the transmission 25 mm (0.984 in) off
the ground. Using a soft-faced hammer,
lightly tap the main housing to break the
gasket seal. 12. Position the intermediate housing and gear
assembly on the Gear Pack Fixture.
• Securely fasten the holding plate to a sturdy
work bench.
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2008 F-250, 350, 450, 550 Super Duty, 7/2007

13. Remove the 2 roll pins and the low/reverse/5th
gear main shift rail driver.
• Use a hammer and punch or an air hammer
and roll pin remover.
15. Remove the lower shift finger and the main

shift rail.
1 Remove the lower shift finger.
X Rotate the rail driver counterclockwise
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and pull outward to remove.
14. NOTE: The shift finger is also the 1st/2nd and
3rd/4th rail driver. 2 Remove the main shift rail.
Remove the lower roll pins.
and roll pin remover to remove.
• For vehicles equipped with a diesel engine,
the shift finger is short. For vehicles
equipped with a gas engine, the shift finger
is long.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

16. Align the interlock plate into 2nd gear position,
engage 2nd gear, then remove the two 5th gear
shift fork roll pins.
• Discard the roll pins.
19. NOTE: Make sure the interlock plate is in the

low/reverse gear position before removing. Shift
the transmission into low gear.
Remove the low/reverse gear shift fork and
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shift rail.
• Align the interlock plate into the low/reverse
gear position. Remove the shift rail by
17. Remove the 5th gear shift fork and shift rail. tapping the shift fork with a soft-faced
• Align the interlock plate into the 5th gear hammer while pulling up on the shift rail
position. Remove the shift rail by tapping and fork.
the shift fork with a soft-faced hammer
while pulling up on the shift rail.
18. Remove the 2 low/reverse gear shift fork roll

pins.
• Discard the roll pins.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

20. NOTE: The shift rail detents can be difficult to
remove. Using a heat gun, apply heat to the
intermediate plate to ease removal.
Remove the shift rail detents, if necessary.
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21. On Four-Wheel Drive (4WD) vehicles, remove
and discard the snap ring.
23. Remove the mainshaft rear bearing and the

output bearing thrust washer from the low and
reverse assembly.
• Inspect the bearing for wear or damage.
Install a new bearing as necessary.
• Always install new bearings and cups as a
set.
22. Using the Shaft Protector Set and the 2 or 3
Jaw Puller, remove the mainshaft rear bearing,
the output bearing thrust washer, mainshaft low
gear, the mainshaft low gear bushing, the
synchronizer assembly (low and reverse) and
the mainshaft reverse gear.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

24. Remove the mainshaft needle bearings.
• Inspect the bearings for wear or damage.
Install new bearings as necessary.
27. Check the clearance between the synchronizer

ring and the gear.
1 Place the synchronizer ring onto the
synchronizer sliding sleeve. Position the
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25. Remove the low gear from the low and reverse synchronizer ring on the gear.
synchronizer assembly. 2 Insert a feeler gauge and measure the
• Inspect the low and reverse gears for wear clearance, while applying pressure and
or damage. Install new gears as necessary. rotating the synchronizer ring. The clearance
should be the same around the entire
circumference.
X Place the feeler gauge between the ring
and gear. The ring has a raised section,
inserting the feeler gauge past the teeth
will give a incorrect reading.
X If the clearance is less than 1.0 mm
(0.039 in) for low or reverse gear, install
a new synchronizer assembly, low gear or
reverse gear to obtain correct
specification.
26. Disassemble the low and reverse synchronizer

assembly.
• Inspect the components for wear or damage.
Inspect the internal surface of the
synchronizer rings for a contact pattern. The
contact pattern should be the same on the
entire internal circumference of the ring.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

28. Remove the mainshaft needle bearing.
31. Remove the countershaft rear thrust washer.
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32. Remove the 5th gear.
29. For vehicles equipped with a diesel engine,
remove the low gear thrust washer.
30. Remove and discard the snap ring.

• This is a selective fit snap ring.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

33. Remove the countershaft needle bearing.
36. Disassemble the countershaft 5th gear

synchronizer assembly.
34. Remove the interlock plate bolts. • Inspect the components for wear or damage.
Inspect the internal surface of the
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synchronizer ring for a contact pattern. The
contact pattern should be the same on the
entire internal circumference of the ring.
35. NOTE: Do not use power tools to remove.

NOTE: Make sure the shift rails are not
binding while pulling up on the intermediate
housing.
Using the Shaft Protector Set and Front Wheel
Hub Remover/Installer with Centerplate Legs,
remove the countershaft bushing, the
countershaft 5th gear synchronizer assembly and
the intermediate housing.
• When installing the Centerplate Legs,
position them opposing one another.
• Inspect the countershaft 5th gear
synchronizer, countershaft bushing and the
intermediate plate for wear or damage.
Install new components as necessary.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

37. Check the clearance between the synchronizer 39. Remove the interlock plate, the 1st/2nd and
ring and the gear. 3rd/4th shift fork and shift rail assemblies.
synchronizer sliding sleeve. Position the
synchronizer ring on the gear.
2 Insert a feeler gauge and measure the
clearance, while applying pressure and
rotating the synchronizer ring. The clearance
circumference.
and gear. The ring has a raised section.
Inserting the feeler gauge past the teeth
will give an incorrect reading.
(0.039 in) for 5th gear, install a new 40. Inspect all the shift fork pads and centers for
wear or damage. Install new shift forks as
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synchronizer assembly or 5th gear to
obtain correct specification. necessary.
38. NOTICE: To prevent damage, do not heat 41. NOTICE: To prevent damage, do not heat
the mainshaft rear bearing, the countershaft the bearings higher than 150°C (302°F)
or mainshaft rear thrust washer, the maximum.
mainshaft bushing or the countershaft Inspect the mainshaft middle bearing, the
bushing higher than 150°C (302°F) countershaft middle bearing and the bearing
maximum. cups in the intermediate housing for wear or
NOTE: Make sure the components are heated damage. Install new components as necessary.
to 150°C (302°F) for reassembly. • Always install new bearings and cups as a
New or original components should be heated set.
in advance of the assembly procedure. Heating • The bearings should be heated to install.
will ease the assembly process. Place the Place the bearings in the Gear/Bearing
mainshaft rear bearing, the countershaft rear Heater.
thrust washer, the countershaft bushing, the rear
mainshaft bearing and the mainshaft low gear
bushing into the Gear/Bearing Heater.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

42. Remove the countershaft rear bearing spacer.
43. Remove the countershaft from the Gear Pack

Fixture and set it aside.
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2008 F-250, 350, 450, 550 Super Duty, 7/2007


Mainshaft Special Tool(s)
Guide, Thrust Washer
Special Tool(s) 308-415
2 or 3 Jaw Puller
205-D027 (D80L-1013-A) or
equivalent
Installer, Wheel Speed Sensor

Ring
206-059 (T94P-20202-B1)
17.5 Ton Press
014-00021
Puller, Bearing
205-D064 (D84L-1123-A) or
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equivalent
Dial Indicator Gauge with
Holding Fixture
100-002 (TOOL-4201-A)
Removal Screw, Bearing Tube

308-092 (T84T-7025-B)
Fixture, Gear Pack

308-381
Remover, Bearing Collet Sleeve

308-029 (T75L-7025-G)
Gauge, Clutch Housing

308-021 (T75L-4201-A)
Remover/Installer, Bearing Tube

308-052 (T77J-7025-B)
Gear/Bearing Heater
164-R3900
Remover/Installer, Thrust
Washer Bearing Cup
308-416
(Continued)
(Continued)

Special Tool(s)
Remover/Installer, Transmission
Bearing Collet
308-132 (T87T-7025-FH)
Shaft Protector Set

205-DS004 (D80L-625-A) or
equivalent
Mainshaft Components — Disassembled View
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Item Part Number Description Item Part Number Description
1 7025 Input shaft bearing 6 7124 Synchronizer assembly, 3rd
2 7017 Input shaft and 4th
3 7046 Input shaft rear oil dam 7 7196 Mainshaft 3rd gear
4 7120 Input shaft pocket bearing 8 7N318 Mainshaft 2nd and 3rd gear
bushings
5 7B331 Snap ring (kit)
9 7K169 Mainshaft needle bearing (3rd
(Continued) gear)
(Continued)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Item Part Number Description
10 7056 Mainshaft 2nd gear thrust
washer
11 7103 Mainshaft 2nd gear
12 7K169 Mainshaft needle bearing
(2nd gear)
13 7124 Synchronizer assembly, 1st
and 2nd
14 7K169 Mainshaft needle bearing (1st
gear)
15 7100 Mainshaft 1st gear
16 7061 Mainshaft
17 7N430 Mainshaft center bearing and 3. Using the Shaft Protector Set, 2 or 3 Jaw Puller
bearing cup and the Bearing Puller, remove and discard the
18 7K322 Mainshaft needle bearing input shaft bearing.
(reverse gear)
19 7142 Mainshaft reverse gear
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20 7124 Synchronizer assembly, low
and reverse
21 7K322 Mainshaft needle bearing
(low gear)
22 7D305 Mainshaft low gear bushing
23 7Z451 Mainshaft low gear
24 7E254 Output bearing thrust washer
25 7R205 Mainshaft rear bearing
26 7B331 Snap ring (kit)
Disassembly
4. Remove and discard the input shaft rear oil
1. Rotate the mainshaft. Position the mainshaft in dam.
the Gear Pack Fixture with the input shaft
pointing upward.
2. NOTE: Installing a new input shaft will affect

mainshaft clearance. Carry out a mainshaft
clearance measurement. For additional
information, refer to the Transmission Assembly
procedures in this section.
Remove the input shaft.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

5. Inspect the input shaft and input shaft bearing
for damage or wear. For additional information,
refer to Section 308-00.
• Inspect the input shaft splines for wear and
damage. Install a new shaft as necessary.
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6. NOTICE: To prevent damage, do not heat
the bearing higher than 150°C (302°F).
A new input shaft bearing should be heated in
advance of the assembly procedure. Heating
components will ease the assembly process.
Place the input shaft bearing into the
Gear/Bearing Heater. Make sure the bearing is
heated to 150°C (302°F). 8. Remove and discard the snap ring.
7. Using the Bearing Tube Remover/Installer with

the Bearing Tube Removal Screw, Transmission
Bearing Collet Remover/Installer and the
Bearing Collet Sleeve Remover, remove the
input shaft pocket bearing.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

9. Using the 2 or 3 Jaw Puller, Shaft Protector Set 11. Check the clearance between the synchronizer
and the Bearing Puller, remove the 3rd and 4th ring and the gear.
synchronizer assembly and 3rd gear. 1 Place the synchronizer ring onto the
• Inspect 3rd gear for wear or damage. Install synchronizer sliding sleeve. Position the
a new gear as necessary. synchronizer ring on the gear.
2 Insert a feeler gauge and measure the
rotating the synchronizer ring. The clearance
circumference.
and gear clutching teeth. The ring has a
raised section, inserting the feeler gauge
past the teeth will give an incorrect
reading.
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(0.039 in), install a new synchronizer
assembly.
10. Disassemble the 3rd and 4th synchronizer

12. Remove the mainshaft needle bearing.
assembly.
• Inspect the components for wear or damage.
Install new components as necessary.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

13. NOTE: When installing the Bearing Puller,
make sure it is installed above the mainshaft
bearing race.
Using the 17.5 Ton Press and the Bearing
Puller, press the mainshaft gear bushing off the
mainshaft.
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14. Using the 17.5 Ton Press and the Bearing
Puller, press the mainshaft 2nd gear thrust
washer, the mainshaft 2nd gear, the mainshaft
needle bearing, the mainshaft gear bushing, 1st
and 2nd synchronizer assembly and mainshaft
1st gear.
• Inspect the gears and bearing for wear or 16. Using the 17.5 Ton Press and the Bearing
damage. Install new components as Puller, remove the mainshaft center bearing.
necessary. • Inspect the bearing for wear or damage.
15. Remove the mainshaft 1st gear needle bearing.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

17. Disassemble the 1st and 2nd synchronizer 19. NOTICE: To prevent damage, do not heat
assembly. bearings, thrust washers, bushings or the
• Inspect the components for wear or damage. synchronizer bodies higher than 150°C
Install a new synchronizer assembly as (302°F).
necessary. New or original components should be heated
in advance of the assembly procedure. Heating
the specified components will ease the assembly
process. Place the input shaft pocket bearing,
the mainshaft second gear thrust washer, the
mainshaft center bearing, the synchronizer
bodies and the mainshaft gear bushings into the
Gear/Bearing Heater.
Assembly
1. Carry out the following:

• Inspect and install new mainshaft gears if
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chipped, burred or badly worn.
18. Check the clearance between the synchronizer • Check the mainshaft gear end play. Install a
ring and the gear clutching teeth. new gear if the end play is not within
specification.
synchronizer sliding sleeve. Position the • Inspect and install a new mainshaft if it is
synchronizer ring on the gear. out of round or worn, if the bearing surface
is scored or the splines are worn or
2 Insert a feeler gauge and measure the damaged.
rotating the synchronizer ring. The clearance • Inspect and install a new speedometer drive
should be the same around the entire gear if the gear teeth are worn or broken.
circumference.
2. NOTICE: Do not reassemble the mainshaft
X Place the feeler gauge between the ring dry. Apply lubricant throughout the
and gear clutching teeth. The ring has a assembly procedure or damage to the
raised section, inserting the feeler gauge components can occur.
past the teeth will give an incorrect
reading. Lubricate all mainshaft components with the
recommended transmission lubricant during
X If the clearance is less than 1.0 mm reassembly.
(0.039 in), install a new synchronizer
assembly.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

3. Install the center mainshaft bearing.
• Make sure the bearing is installed against
the stop on the mainshaft.
6. Install the 3 synchronizer rings for 1st gear.

• Make sure the tabs on the synchronizer ring
are in the slots on the gear.
• Make sure to align the notches on the
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4. Using the 17.5 Ton Press and the Bearing synchronizer body with the tabs on the
Puller, position the mainshaft on the press with synchronizer ring.
the input end facing upward.
• Using a hammer and punch, remove the
bearing cup from the intermediate housing,
then install it on the bearing. This will
prevent any damage to the bearing during
installation.
5. Install the 1st gear bearing and 1st gear.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

7. Using the Thrust Washer Bearing Cup
Remover/Installer, press the 1st and 2nd gear
synchronizer body into place.
• The numbers on the synchronizer hub must
face upward.
• Make sure to align the notches on the
synchronizer body with the tabs on the
synchronizer ring.
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8. NOTE: Install the synchronizer sliding sleeve
with the flats aligned with the detent notches.
Install the synchronizer sliding sleeve.
• The sliding sleeve has 3 flat areas which 9. Install the synchronizer spring and plate, then
need to line up with the detent area of the tilt the plate up and install the detent ball.
synchronizer body.
• If the springs are difficult to install, check
the alignment of the synchronizer sliding
sleeve flat areas.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

10. NOTE: Position the synchronizer into the 13. Install the 2nd gear.
neutral position. • Make sure to align the tabs on the
Install the synchronizer rings for 2nd gear. synchronizer ring with the slots on the gear.
• Align the tabs on the synchronizer rings
with the slots in the synchronizer body.
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14. Using the Thrust Washer Guide and the Thrust
Washer Bearing Cup Remover/Installer, press
11. Install the mainshaft 2nd gear bushing. the mainshaft 2nd gear thrust washer into place.
12. NOTE: Let the mainshaft 2nd gear bushing 15. Using a suitable tool, install the mainshaft 3rd
cool down for 2-4 minutes before trying to gear bushing on the mainshaft.
install the mainshaft needle bearing. • Pull the 1st/2nd gear sliding sleeve into the
Install the mainshaft needle bearing. neutral position.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

16. NOTE: Let the mainshaft 3rd gear bushing
cool down for 2-4 minutes before trying to
install the mainshaft needle bearing.
Install the mainshaft needle bearing.
19. Install a new snap ring.

• Install the snap ring with the small holes
facing upward.
• The snap ring is a selective fit. The correct
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snap ring should completely fill the groove
17. Install the mainshaft 3rd gear and synchronizer when seated.
ring.
18. Install the 3rd and 4th gear synchronizer body.

• The numbers on the synchronizer body must
face upward.
• Make sure to align the synchronizer body
notches with the tabs on the synchronizer
ring.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

20. NOTICE: Press the input shaft pocket
bearing onto the mainshaft by the inner race
only. Pressing on the outer race will damage
the bearing.
Press the input shaft pocket bearing into place.
• Make sure the bearing is correctly seated. At
the bottom of the bearing, there should be
no gap. At the top of the bearing, check for
a small amount of the mainshaft to be above
the inner bearing race.
24. NOTICE: Do not drive against the bearing

cone. Drive against the inner race only or
damage to the components can occur.
Using a suitable driver, install a new input shaft
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bearing.
• Seat the bearing against its stop.
21. Remove the mainshaft from the press and

reinstall it in the Gear Pack Fixture.
22. Install and position the synchronizer sliding

sleeve down on the synchronizer body, install
the springs and detents.
23. Install the synchronizer ring, then move the

synchronizer sliding sleeve up on the
synchronizer body.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

25. Using the Wheel Speed Sensor Ring Installer,
install the input shaft rear oil dam.
• Rotate the input shaft to make sure the input
shaft rear oil dam is completely seated.
28. Using the Dial Indicator Gauge with Holding

Fixture and the Clutch Housing Gauge, check
the axial gear clearance at the mainshaft 2nd
gear.
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26. Install the input shaft.
• Fill the input shaft pocket with a suitable
engine assembly white grease.
27. NOTE: If the following axial gear clearances

are not within specification, it will be necessary
to disassemble and reinspect.
Using the Dial Indicator Gauge with Holding
the axial gear clearance at the mainshaft 1st
gear.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

29. Rotate the mainshaft with the input shaft facing
downward. Using the Dial Indicator Gauge with
Holding Fixture and the Clutch Housing Gauge,
check the axial gear clearance at the mainshaft
3rd gear.
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2008 F-250, 350, 450, 550 Super Duty, 7/2007


Countershaft Bearing Disassembly
Special Tool(s) 1. Using the Shaft Protector Set, 2 or 3 Jaw Puller

and the Drive Pinion Bearing Cone Remover,
2 or 3 Jaw Puller remove the front countershaft bearing.
205-D027 (D80L-1013-A) or
equivalent
Gear/Bearing Heater
164-R3900
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Puller, Bearing
205-D064 (D84L-1123-A) or
equivalent
Remover, Drive Pinion Bearing

Cone
205-D002 (D79L-4621-A) or
equivalent
Remover/Installer, Thrust 2. Using the Bearing Puller, remove the rear

Washer Bearing Cup
308-416 countershaft bearing.
Shaft Protector Set

205-DS004 (D80L-625-A) or
equivalent

3. Inspect the countershaft and bearings for wear
or damage. Install new components as
necessary. For additional information, refer to
Section 308-00.
• Always install new bearings and cups as a
set.
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4. Inspect and install a new countershaft if the
teeth are chipped or excessively worn.

the countershaft middle bearing or the
countershaft front bearing higher than 150°C
(302°F) maximum. 2. Remove the bearing from the Gear/Bearing
New or original components should be heated Heater, then install the rear countershaft
in advance of the assembly procedure. Heating bearing.
the specified components will ease the assembly • If necessary, use the Thrust Washer Bearing
process. Place the countershaft middle bearing Cup Remover/Installer to seat the bearing.
and the countershaft front bearing into the
Gear/Bearing Heater.
Assembly
1. Remove the bearing from the Gear/Bearing

Heater, then install the countershaft bearing.
• If necessary, use the Thrust Washer Bearing
Cup Remover/Installer to seat the bearing.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


Transmission Case Special Tool(s)
Remover/Installer, Front Wheel
Special Tool(s) Hub
204-069 (T81P-1104-C)
Handle
205-D055 (D81L-4000-A) or
equivalent
Slide Hammer
100-001 (T50T-100-A)
Installer, Centerplate Front

Bearing Cup
308-390
Universal Puller Set

303-DS005 (D80L-100-A) or
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equivalent
Installer, Input Shaft Bearing
Cup
308-391
Disassembly
Installer, Shift Rail Needle 1. Using the Slide Hammer with the Bearing Cup
Bearing Remover, remove the countershaft bearing cup
308-130 (T87T-7025-DH)
and shim. Discard the shim.
• Inspect the countershaft bearing cup for
wear or damage. Install a new cup as
necessary.
Remover, Bearing Cup • Install a new cup if a new countershaft front
308-047 (T77F-1102-A) bearing was installed.
Remover, Input Shaft Bearing

Cup
308-S392
(Continued)

2. NOTE: Oil pump removal is only necessary if
a large amount of particles were in the
transmission during disassembly.
Remove the oil pump snap ring.
5. Using the Front Wheel Hub Remover/Installer

with the Input Shaft Bearing Cup Remover,
remove the input shaft bearing cup.
• Inspect the input shaft bearing cup for wear
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or damage. Install a new cup as necessary.
3. Remove the oil pump assembly. • Install a new cup if the input shaft bearing
• Using a pair of Vise Grips, pull upward was installed new.
on the center shaft.
• Thoroughly clean the oil pump housing.
Inspect the oil pump for wear or damage.
Install a new oil pump assembly as
necessary.
6. Remove the input shaft oil dam bearing ring.
4. Using a brass drift, dent the input shaft oil

baffle for puller tool clearance.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

7. Remove the input shaft shim. Discard the shim.
11. Remove the Power Take-Off (PTO) cover.
8. Remove the oil trough.
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12. NOTE: Inspect the bearing for wear or damage
before removing.
9. Remove the guide tube. Using the Universal Puller Set, remove and
discard the shift rail bearing.
10. Remove the input shaft oil seal.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Assembly
1. Using the Shift Rail Needle Bearing Installer

with the Handle, install a new shift rail bearing.
4. Using the Handle and the Centerplate Front

Bearing Cup Installer, install the countershaft
bearing cup.
• Do not install the shim at this time. The
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bearing preload adjustment procedure will
2. NOTE: Fill the oil pump housing with a determine the thickness of the shim to be
suitable engine assembly white grease. installed.
Install the oil pump assembly.
1 Install the rotor into the pump housing.
2 Install the oil pump body.
3 Install a new oil pump snap ring.
5. The case assembly will be completed during the

assembly procedure. For additional information,
refer to Transmission in the Assembly portion
of this section.
3. Using the Input Shaft Bearing Cup Installer

with the Handle, install the input shaft bearing
cup.
• Do not install the oil trough, input shaft
shim or the input shaft oil dam bearing ring
at this time. The bearing preload adjustment
procedure will determine the thickness of
the shim to be installed.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


Intermediate Housing Special Tool(s)
Installer, Shift Rail Needle
Special Tool(s) Bearing
308-130 (T87T-7025-DH)
Actuator Pin (Dia 3/16 inch)
303-D011 (D80L-100-G) or
equivalent
Slide Hammer
100-001 (T50T-100-A)
Collet, 3/4 inch to 7/8 inch

303-D019 (D80L-100-Q) or
equivalent
Disassembly
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Handle 1. Using a brass drift, remove the intermediate
205-153 (T80T-4000-W) housing countershaft bearing race.
Heat Gun
107-R0300 or equivalent
Installer, Centerplate Mainshaft

Bearing Cup
308-389 2. Using a brass drift, remove the intermediate
housing mainshaft bearing race.
Installer, Countershaft Bearing

Cup
308-388
(Continued)

3. Using the Slide Hammer with the Actuator Pin 2. Using the Centerplate Mainshaft Bearing Cup
and a 3/4 to 7/8 inch Collet, remove and Installer and the Handle, install the intermediate
discard the center shift rail bearing. housing mainshaft bearing race.
• Using the Heat Gun, heat the bearing area
of the housing.
Assembly
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1. Using the Countershaft Bearing Cup Installer 3. Using the Shift Rail Needle Bearing Installer
and the Handle, install the intermediate housing and the Handle, install the center rail shift
countershaft bearing race. bearing.
• Using the Heat Gun, heat the bearing area • Using the Heat Gun, heat the bearing area
of the housing. of the housing.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


Extension Housing
Special Tool(s)
Handle
205-D055 (D81L-4000-A) or
equivalent
Heat Gun
2. Remove the reverse idler shaft support.
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Installer, Countershaft Rear
Bearing
308-384
Installer, Shift Rail Needle

Bearing
308-130 (T87T-7025-DH)
3. Remove the reverse idler gear.
• Inspect the gear for wear or damage.
• Check the teeth for chips or burrs.
Universal Puller Set • Install a new gear as necessary.

303-DS005 (D80L-100-A) or
equivalent
Disassembly
1. NOTE: To aid installation, index-mark the bolt

hole position on the reverse idler shaft.
Remove the reverse idler shaft bolt and seal.
Discard the seal.

4. Remove the reverse idler gear bearing. 7. NOTE: Inspect the bearing for wear or damage
• Inspect the bearing for wear or damage. before removing.
• Install a new bearing as necessary. Using the Universal Puller Set, remove and
discard the shift rail bearing.
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5. Remove the reverse idler shaft.
8. Remove the reverse lamp switch and seal.
Discard the seal.
6. NOTE: Inspect the countershaft front bearing

for wear or damage before removing.
9. Remove and discard the output oil seal.
Using the Universal Puller Set, remove and
discard the countershaft front bearing.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

10. Inspect the magnet. Make sure it is securely 2. Using the Shift Rail Needle Bearing Installer
attached in the extension housing. with the Handle, install a new shift rail bearing.
• Using a Heat Gun, heat the bearing area of
the housing to ease installation.
Assembly
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1. NOTE: A new extension housing will not have 3. Using the Countershaft Rear Bearing Installer
a magnet. A new magnet must be installed. and the Handle, install a new countershaft
Apply adhesive to the magnet and install. bearing.
• Only apply adhesive to the housing side of • Using a Heat Gun, heat the bearing area of
the magnet. the housing to ease installation.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

4. NOTE: Make sure the hole in the shaft aligns 6. Install the idler shaft bolt with a new seal.
with the hole in the extension housing. • Tighten to 23 Nm (17 lb-ft).
NOTE: The oil grooves on the gear face the
output side of the extension housing.
Install the reverse idler shaft, reverse idler gear
bearings and reverse idler gear.
7. Install the reverse lamp switch with a new seal.
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• Tighten to 20 Nm (177 lb-in).
8. Install the new output oil seal after the bearing

preload is completed during transmission
5. Install the reverse idler shaft support.
assembly.
• The ribs on the reverse idler shaft support
face upward.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


Transmission Special Tool(s)
Holding Fixture, Drive Pinion
Special Tool(s) Flange
205-126 (T78P-4851-A)
Dial Indicator Gauge with
Holding Fixture
100-002 (TOOL-4201-C)
Installer, Centerplate Front

Bearing Cup
308-390
Fixture, Gear Pack
308-381
Installer, Input Shaft Bearing

Cup
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308-391
Gauge, Clutch Housing
308-021 (T75L-4201-A)
Installer, Input Shaft Oil Seal

308-379
Gear/Bearing Heater
164-R3900

(4x4)
308-383
Handle
205-D055 (D81L-4000-A) or
equivalent

(4x2)
308-382
Heat Gun
Remover, Bearing Cup

308-047 (T77F-1102-A)
(Continued)
(Continued)

Special Tool(s) Material
Remover, Input Shaft Bearing Item Specification
Cup MERCON V Automatic MERCON V
308-S392 Transmission Fluid
(US); CXT-5-LM12
(Canada)
Motorcraft Full WSD-M2C200-C
Synthetic Manual
Remover/Installer, Front Wheel Transmission Fluid
Hub XT-M5-QS
204-069 (T81P-1104-C)
TA-16
Premium Long-Life ESA-M1C75-B
Grease
XG-1-C or XG-1-K (US);
Remover/Installer, Thrust CXG-1-C (Canada)
Washer Bearing Cup Threadlock 262 WSK-M2G351-A6
308-416
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TA-26
Threadlock and Sealer WSK-M2G351-A5
TA-25
Slide Hammer
100-01 (T50T-100-A)

mm)
308-127 (T87T-7025-AH)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Transmission Internal Components — Disassembled View
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2008 F-250, 350, 450, 550 Super Duty, 7/2007

1 7050 Guide tube 24 7K322 Mainshaft reverse and low
2 7029 Input shaft shim (selective fit) gear bearing
3 7046 Input shaft oil dam bearing 25 7D305 Mainshaft reverse gear
ring bushing
4 7025 Input shaft bearing and 26 7142 Mainshaft reverse gear
bearing cup 27 7E254 Output bearing thrust washer
5 7017 Input shaft 28 7R205 Mainshaft rear bearing
6 7046 Input shaft rear oil dam 29 7B331 Snap ring kit
7 7120 Input shaft pocket bearing 30 7089 Transmission flange (Rear
8 7B331 Snap ring kit Wheel Drive (RWD)
vehicles)
9 7124 Synchronizer assembly, 3rd
and 4th gear 31 7045 Transmission flange locknut
(RWD vehicles)
10 7196 Mainshaft 3rd gear
32 7029 Countershaft shim (selective
11 7N318 Mainshaft 2nd and 3rd gear fit)
bushings
33 7065 Countershaft front bearing
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12 7K169 Mainshaft needle bearing and bearing cup
13 7056 Mainshaft 2nd gear thrust 34 7113 Countershaft
ring
35 7065 Countershaft middle bearing
14 7103 Mainshaft 2nd gear and bearing cup
15 7K169 Mainshaft needle bearing 36 7115 Countershaft rear bearing
16 7124 Synchronizer assembly, 1st spacer
and 2nd gear 37 7124 Synchronizer assembly,
17 7K169 Mainshaft needle bearing countershaft 5th gear
18 7100 Mainshaft 1st gear 38 7069 Countershaft bushing
19 7061 Mainshaft 39 7K335 Countershaft needle bearing
20 7N430 Mainshaft middle bearing and 40 7158 Countershaft 5th gear
bearing cup 41 7A385 Countershaft rear thrust
21 7K322 Mainshaft needle bearing washer
22 7Z451 Mainshaft low gear 42 7B331 Snap ring kit
23 7124 Synchronizer assembly, low 43 7065 Countershaft rear bearing
and reverse gear
(Continued)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Transmission Internal Components — Disassembled View
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2008 F-250, 350, 450, 550 Super Duty, 7/2007

1 7052 Input oil seal 14 7052 Output seal
2 7005 Main case 15 7A039 Extension housing (Rear
3 7D362 Shift rail bearings Wheel Drive (RWD)
vehicles)
4 7005 Oil trough
16 7A039 Extension housing
5 7006 Middle case (Four-Wheel Drive (4WD)
6 7E213 Check valve vehicles)
7 7917 Check valve snap ring 17 7E290 Magnets
8 7A010 Drain plug 18 7D362 Shift rail bearings
9 7B362 Dowel pin 19 7141 Reverse idler gear
10 7A103 Oil pump body 20 7E139 Reverse idler bearing
11 7B150 Oil pump housing 21 7140 Reverse idler shaft
12 7R194 Oil pump snap ring 22 7723 Reverse idler shaft support
13 7B362 Dowel pin 23 7A010 Fill plug
(Continued)
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2008 F-250, 350, 450, 550 Super Duty, 7/2007

Transmission Shift Components — Disassembled View
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2008 F-250, 350, 450, 550 Super Duty, 7/2007

Item Part Number Description 1. NOTICE: Do not reassemble the transmission
1 7210 Shift lever (lower) dry. Apply lubricant throughout the
assembly procedure or damage to the
2 7C371 Shift lever blocks
components can occur.
3 7277 Shift lever boot
Lubricate all bearings, gears and synchronizers
4 — Shift housing bolt (4
required) with the recommended transmission lubricant
during reassembly.
5 7203 Shift housing
6 7811 Shift finger 2. Index-mark the countershaft in relation to the
7 7B096 Roll pins (double) (14 oil pump slot.
required)
8 7289 Shift fork (1st and 2nd)
9 7240 Shift rail
10 7R359 Main shift rail
11 7289 Shift fork (3rd and 4th)
12 7C113 Shift rail
13 7229 Shift position block
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14 7K201 Shift interlock plate
15 7L013 Detent plug
16 7N120 Detent spring
17 7247 Shift rail detent
18 7243 Main shift rail driver
19 7H419 Shift fork (5th)
20 7682 Shift rail
21 7244 Shift fork (low and reverse)
22 7H418 Shift rail
23 7Z415 Main shift detent
24 7E218 Detent plunger
25 15520 Reverse lamp switch
NOTE: Transmission fluid usage:

• Gas engines use MERCON V Automatic
Transmission Fluid.
• Diesel engines use Motorcraft Full Synthetic
Fluid.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

3. Position the countershaft to the mainshaft on
the Gear Pack Fixture.
6. Install the interlock plate.

• The stamped part numbers on the interlock
plate must face toward the input shaft.
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4. Install the countershaft rear bearing spacer.
7. Install and position the intermediate housing on
• The countershaft rear bearing spacer can be
the mainshaft, the countershaft and the shift
installed either way.
rails.
• Make sure the detents are clear of the bore
area on the intermediate housing.
5. Install the 1st/2nd and 3rd/4th shift fork and

shift rail assemblies.
• The detent groove on the rail faces upward
or to the output shaft.
• All shift forks and rails use double roll pins.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

8. Install the interlock plate bolts. 11. NOTICE: To prevent damage, do not heat
• Tighten to 10 Nm (89 lb-in). the countershaft bushing higher than 150°C
(302°F) maximum.
Remove the countershaft bushing from the
Gear/Bearing Heater, then install the
countershaft bushing.
9. Assemble the 5th gear synchronizer assembly.
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12. NOTE: Allow the countershaft bushing to cool
for 2-4 minutes before installing the
countershaft needle bearing.
Install the countershaft needle bearing.
10. Install the 5th gear synchronizer assembly.

• Install the 5th gear synchronizer with the
snap ring on the synchronizer body facing
down against the intermediate housing.
• The 5th gear synchronizer will slide into
place and does not require heat to install.
13. Install the 5th gear.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

14. Install the countershaft rear thrust washer and a
new snap ring.
snap ring should completely fill the groove
when seated.
• Install the snap ring with the small holes
upward.
• Make sure the snap ring is completely
seated, with one tab of the snap ring under
the gear tooth.
17. Install the low gear.
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15. For vehicles equipped with a diesel engine,
install the low gear thrust washer.
18. Install the low and reverse synchronizer

assembly and synchronizer ring.
• Install the low/reverse gear synchronizer
with the shoulder of the sliding sleeve
facing down to the low gear.
• The low/reverse synchronizer body will slide
into place and does not require heat to
install.
16. Install the 2 mainshaft low gear needle

bearings.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

19. NOTICE: To prevent damage, do not heat 21. Install the reverse gear. Pull the synchronizer
the reverse gear bushing higher than 150°C sliding sleeve into the neutral position.
(302°F) maximum.
Remove the mainshaft reverse gear bushing
from the Gear/Bearing Heater, then install the
mainshaft bushing.

the output bearing thrust washer higher than
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150°C (302°F) maximum.
Remove the output bearing thrust washer from
20. NOTE: Allow the mainshaft reverse gear the Gear/Bearing Heater, then using the Thrust
bushing to cool for 2-4 minutes before Washer Bearing Cup Remover/Installer, install
installing mainshaft needle bearing. the output bearing thrust washer.
Install the mainshaft needle bearing.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

23. NOTICE: To prevent damage, do not heat 25. Using the Dial Indicator Gauge with Holding
the rear mainshaft output bearing higher Fixture and the Clutch Housing Gauge, check
than 150°C (302°F) maximum. the axial gear clearance at low gear.
Remove the mainshaft output bearing from the • If not within specifications, disassemble and
Gear/Bearing Heater, then using the Thrust reinspect.
Washer Bearing Cup Remover/Installer, install
the rear mainshaft output bearing.
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26. Using the Dial Indicator Gauge with Holding
24. Using the Dial Indicator Gauge with Holding the axial gear clearance at reverse gear.
Fixture and the Clutch Housing Gauge, check • If not within specifications, disassemble and
the axial gear clearance at 5th gear. reinspect.
• If not within specifications, disassemble and
reinspect.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

27. NOTE: The snap ring is used on Four-Wheel 29. Using a 5 mm (3/16 in) punch, align the roll
Drive (4WD) vehicles only. pin hole with the top hole of the shift fork.
Install a new snap ring. Install the double roll pin in the lower hole,
then install a roll pin in the upper hole.
snap ring should completely fill the groove • Do not hit the sealing surface of the
when seated. intermediate plate.
• Install the snap ring with the small holes • Make sure the slot of the roll pin is facing
upward. away from the shift rail.
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28. NOTE: Using an oil stone or emery cloth, 30. NOTE: Using an oil stone or emery cloth,
lightly condition the shift rails and clean them lightly condition the shift rails and clean them
with transmission fluid before installing the with transmission fluid before installing the
shift forks and shift rails. shift forks and rails.
NOTE: Move the interlock plate into the 5th NOTE: Move the interlock plate into the
gear position. low/reverse position.
Install the 5th gear shift fork and the shift rail. Install the low/reverse gear shift fork and the
shift rail.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

31. Using a 5 mm (3/16 in) punch, align the roll
pin hole with the top hole of the shift fork.
Install the double roll pin in the lower hole,
then install a roll pin in the upper hole.
• Make sure the slot of the roll pin is facing
away from the shift rail.
34. Install the lower shift finger and a new large

roll pin, then install a new small roll pin.
• Make sure the lower shift finger cup is
down.
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• Install the large roll pin with the opening
away from the gearset.
32. Install the 4 shift detent springs and 4 new • Make sure the center of the interlock driver
detent plugs. is aligned with the center of the interlock
plate before installing the small pin.
• Apply gasket maker to the detent plugs
before installing. • Install the small roll pin with the opening
180 degrees from the opening in the large
roll pin. The roll pin should extend equally
from both sides when correctly installed.
33. Install the main shift rail, aligning the center of

the interlock driver with the center of the
interlock plate.
• The part numbers on the main shift rail,
shift position block and shift finger face the
output side of the transmission. The roll pin
groove on the main shift rail with the
shorter distance from the end faces the
output end.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

35. Install the main shift rail driver and a new large
roll pin, then install a new small roll pin.
• Install the large roll pin with the opening
away from the gearset.
• Install the small roll pin with the opening
180 degrees from the opening in the large
roll pin.
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36. NOTE: Only install the bearing cups in the
main case. The following bearing preload
adjustment procedure will determine the
thickness of the shim to be used.
NOTE: For vehicles equipped with gasoline
38. Install the intermediate housing-to-case bolts.
engines, the transmission must be elevated
50-101 mm (1.968-3.976 in), to prevent damage • Tighten to 23 Nm (17 lb-ft).
to the input shaft.
Place the main case on the floor. Align the oil
pump center shaft with the slot in the
countershaft.
37. NOTE: Do not apply sealer at this time.

NOTE: Do not damage the input shaft when
removing it from the Gear Pack Fixture.
NOTE: To aid installation, have an assistant
lower the assembly while another guides the
assembly into the main case.
Using a suitable lifting device, a suitable chain
and 2 S-hooks, lift the intermediate housing and
gear assembly into the case.
• Using the index mark made on the
countershaft, make sure the oil pump center
shaft is aligned with the slot on the
countershaft.
• Lightly tap the intermediate housing onto
the transmission case.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

39. Install the Dial Indicator Gauge with Holding
Fixture and the Clutch Housing Gauge to
measure countershaft clearance.
• Mount the Holding Fixture to the
• Install the Dial Indicator Gauge. Make sure
the indicator is off center on the end of the
countershaft.
• Zero the Dial Indicator Gauge.
41. Install the Dial Indicator Gauge with Holding

Fixture and the Clutch Housing Gauge to
measure mainshaft clearance.
• Mount the Holding Fixture to the
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• Install the Dial Indicator Gauge. Make sure
the indicator is off center on the end of the
mainshaft.
• Zero the Dial Indicator Gauge.
40. NOTE: The Front Wheel Hub

Remover/Installer is installed on the Power
Take-Off (PTO) opening.
Using the Front Wheel Hub Remover/Installer,
measure for countershaft clearance.
• Lift up on the 3rd gear counter.
• Observe the Dial Indicator Gauge reading.
• Add preload specification 0.02 mm (0.0007
in) and 0.09 mm (0.003 in) to the Dial
Indicator Gauge reading to determine shim
thickness range. Countershaft clearance +
0.02 mm (0.0007 in) Preload = Shim size.
Countershaft clearance + 0.09 mm (0.003
in) Preload = Shim size. Choose the shim
between the calculated values for the correct
preload.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

42. Lifting up on the mainshaft, measure the 44. Using a suitable lifting device, a suitable chain
mainshaft clearance. and 2 S-hooks, lift the intermediate housing and
• Lift up on the low gear. gear assembly out of the case.
• Observe the Dial Indicator Gauge reading. • Place the S-hooks in the area where the
bolts were removed.
• Add preload specification 0.02 mm (0.0007
in) and 0.09 mm (0.003 in) to the Dial
Indicator Gauge reading to determine shim
thickness. Measure the thickness of the input
shaft oil dam bearing ring at 3 places and
subtract the highest dimension. Mainshaft
clearance (-) the thickness of the oil dam +
0.02 mm (0.0007 in) Preload = Shim size.
Mainshaft clearance (-) the thickness of the
oil dam + 0.09 mm (0.003 in) Preload =
Shim size. Choose the shim between the
calculated values for the correct preload.
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43. Remove the special tools, then remove the
intermediate housing-to-case bolts. 45. Using the Front Wheel Hub Remover/Installer
and the Input Shaft Bearing Cup Remover,
remove the input shaft bearing cup.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

46. Using the Slide Hammer with the Bearing Cup 48. NOTE: Use a Heat Gun on the case bearing
Remover, remove the countershaft bearing cup. cup area to aid installation.
Install the new shim, then using the Centerplate
Front Bearing Cup Installer and the Handle,
install the countershaft bearing cup.
• Using the clearance measurement plus the
preload, select the appropriate shim.
47. NOTE: Use a Heat Gun on the case bearing

cup area to aid installation.
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Install the new shim, the new input shaft oil
dam bearing ring and the oil trough into the
bearing cup bore, then using the Input Shaft
Bearing Cup Installer with the Handle, install 49. NOTICE: Do not use a silicone sealing
the input shaft bearing cup. compound or damage to the components can
• Using the clearance measurement plus the occur.
preload, select the appropriate shim and NOTE: Use an oil stone or sanding block to
input shaft oil dam bearing ring. clean the intermediate plate and main case
mating surfaces.
tighten the 2 bolts due to the rapid cure time of
the sealant.
Thinly coat the rear sealing surface of the case
and the front sealing surface of the intermediate
housing with gasket maker.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

50. NOTE: For vehicles equipped with gasoline
engines, the transmission must be elevated,
50-101 mm (1.968-3.976 in), to prevent damage
to the input shaft.
NOTE: To aid installation, have an assistant
lower the assembly while another guides the
assembly into the case.
Install the intermediate housing and gear
assembly into the case.
• Using the index mark made on the
countershaft, make sure the oil pump center
shaft is aligned with the slot on the
countershaft. 52. NOTE: Do not wait longer than 10 minutes to
• Lightly tap the intermediate housing onto tighten the bolts due to the rapid cure time of
the transmission case. the sealant.
Thinly coat the rear sealing surface of the
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intermediate housing and the extension housing
with gasket maker. Install the extension housing
and the 19 extension housing-to-case bolts.
53. Apply threadlock and sealer to the threads of

the main shift detent. Install the detent plunger
and the main shift detent.
51. Install the intermediate housing-to-case bolts.

• Apply threadlock and sealer to the
intermediate housing-to-case bolts.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

54. NOTE: Tighten the bolts in a cross pattern.
Apply threadlock and sealer to the threads of
the PTO cover plate bolts. Install a new gasket
and the PTO cover.
57. Install the release lever and clutch release hub

and bearing.
• Lubricate the ball stud and the clutch release
lever. Only apply grease where the clutch
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release lever comes in contact with the pivot
and the release hub and bearing.
55. NOTE: The tool listed is for gasoline equipped
vehicles only. To install the seal for diesel
equipped vehicles, use a suitable 1.75 inch ID x
10 inch pipe. Make sure the seal is flush with
the transmission case.
Using the Input Shaft Oil Seal Installer, install
a new input oil seal.
• Coat the inner diameter of the new input oil
seal with manual transmission fluid.
58. Using the Output Shaft Oil Seal Installer (4x2)

308-382 for RWD or Output Shaft Oil Seal
Installer (4x4) 308-383 for 4WD, install a new
output oil seal.
56. Apply threadlock and sealer to the threads of

the guide tube bolts. Install the guide tube.
• Tighten bolts to 23 Nm (17 lb-ft).
2008 F-250, 350, 450, 550 Super Duty, 7/2007

60. Install the shift housing and the 4 shift
housing-to-case bolts.
• Shift the transmission through all gears to
verify gears shift correctly.
59. NOTE: This step is for 2-Wheel Drive (2WD)

vehicles only.
Apply threadlock 262 to the threads of the
transmission flange locknut. Using the Drive
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Pinion Flange Holding Fixture and the
Mainshaft Locknut (36-mm) Socket, install the
transmission flange and a new output flange 61. Check transmission preload. Shift the
locknut. transmission into reverse and rotate the
• Tighten to 330 Nm (244 lb-ft). mainshaft.
• Drag torque should be 2-8 Nm (18-70 lb-in).
62. Remove the shift housing-to-case bolts and the

shift housing for installation.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


Transmission — Gasoline Engines 4. Install the 4 RH transmission support
crossmember nuts.
Special Tool(s) • Tighten to 70 Nm (52 lb-ft).
Transmission Jack
014-00942
Material
Item Specification
TA-16
MERCON V Automatic MERCON V
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Transmission Fluid 5. NOTE: The transmission mount studs may
(US); CXT-5-LM12 have come out of the insulator when the nuts
(Canada) were removed. Install new insulator studs if
Threadlock and Sealer WSK-M2G351-A5 they came out during removal.
TA-25 Install the transmission mount studs or nuts.
All vehicles • Tighten the studs to 75 Nm (55 lb-ft).
• Tighten the nuts to 81 Nm (60 lb-ft).
1. Using the Transmission Jack, raise and position
the transmission to the engine and clutch.
2. Install the 7 transmission-to-engine bolts.

3. Position the crossmember in the vehicle. Install

the 3 LH transmission support crossmember
bolts.
6. Install the 2 dust cover bolts.

7. Remove the Transmission Jack.

8. Connect the transmission fluid cooler tubes.
14. Install any Power Take-Off (PTO) equipment, if

equipped.
9. Install the clutch slave cylinder. 15. Connect the fuel tubes to the transmission.
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• Rotate the clutch slave cylinder clockwise
45 degrees to lock in position.
16. Connect the reverse lamp switch electrical

connector.
10. Install the starter. For additional information,
refer to Section 303-06B.
11. Install the exhaust Y-pipe. For additional

information, refer to Section 309-00.
12. Install the transfer case, if equipped. For

308-07B.
• If the transfer case control lever assembly
was removed from the transmission, it must
be correctly aligned.
13. NOTE: Make sure the index marks made

Connect the driveshaft. Install 4 new driveshaft
flange bolts.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

17. Connect the wiring harness to the transmission.
21. Apply threadlock and sealer to the gearshift

lever bolt. Install the upper gearshift lever.
18. Refill the transmission to specification. For • Tighten to 35 Nm (26 lb-ft).
additional information, refer to Transmission
Draining and Filling in this section.
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• Refill the transmission with clean
transmission fluid.
19. NOTICE: Do not use a silicone sealing

compound or damage to the components can
occur.
the sealant.
Install the gearshift lever and shift housing
assembly.
• Tighten to 23 Nm (17 lb-ft). 22. Install the shift lever boot.
• Apply gasket maker to the shift housing and
the main case.
20. Install the lower shift lever boot and the 2 23. Position the transfer case shift lever with the
screws. bezel and boot assembly and install the bolt.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

24. Position the bezel and boot assembly and install 25. Verify the shift sequence from 2H to 4L to 2H.
the 2 screws.
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2008 F-250, 350, 450, 550 Super Duty, 7/2007


Transmission — Diesel Engines
Special Tool(s)
Transmission Jack
014-00942
Material
Item Specification 5. NOTE: The transmission mount studs may
Gasket Maker WSK-M2G348-A5 have come out of the insulator when the nuts
TA-16 were removed. Install new insulator studs if
Motorcraft Full WSD-M2C200-C they came out during removal.
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Synthetic Manual Install the 2 transmission mount nuts.
Transmission Fluid
XT-M5-QS • Tighten the studs to 75 Nm (55 lb-ft).
Threadlock and Sealer WSK-M2G351-A5 • Tighten the nuts to 81 Nm (60 lb-ft).
TA-25
All vehicles
1. Using the Transmission Jack, raise and position

the transmission to the engine and clutch.
2. Install the 7 transmission-to-engine bolts.

3. Position the crossmember in the vehicle. Install

the 3 LH transmission support crossmember
bolts.
6. Attach the wire harness to the crossmember.
7. Remove the Transmission Jack.
4. Install the 4 RH crossmember nuts.


8. Connect the transmission fluid cooler tubes. 13. Install any Power Take-Off (PTO) equipment, if
• Tighten to 27 Nm (20 lb-ft). equipped.
9. Install the clutch slave cylinder. 14. Connect the reverse lamp switch electrical
connector.
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• Rotate the clutch slave cylinder clockwise
45 degrees to lock in position.
15. Connect the wiring harness to the transmission.

10. Install the transfer case, if equipped. For 16. Refill the transmission to specification. For
additional information, refer to Section additional information, refer to Transmission
308-07B. Draining and Filling in this section.
• If the transfer case control lever assembly • Refill the transmission with clean
was removed from the transmission, it must transmission fluid.
be correctly aligned.
17. Install the 2 bolts that attach the shift lever to
11. Install the skid plate, if equipped. the transfer case control lever assembly.
12. NOTE: Make sure the index marks made • Tighten to 35 Nm (26 lb-ft).
Connect the driveshaft.
• Tighten the new driveshaft bolts to 111 Nm
(82 lb-ft).
2008 F-250, 350, 450, 550 Super Duty, 7/2007

18. NOTICE: Do not use a silicone sealing 20. Install the upper gearshift lever and bolt.
compound or damage to the components can • Tighten to 35 Nm (26 lb-ft).
occur.
the sealant.
Install the gearshift lever and shift housing
assembly.
• Tighten the shift housing-to-case bolts to 23
Nm (17 lb-ft).
• Apply gasket maker to the shift housing and
the main case.
21. Install the 4 shift lever boot screws.
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19. Install the lower shift lever boot and the 2
screws.
22. Verify the shift sequence from 2H to 4L to 2H.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

ZF-6 Caja Sincronica Z6 Triton

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Available Formats

308-03-1 Manual Transaxle/Transmission — ZF 6-Speed 308-03-1

Taper roller bearing inner 150°C (302°F) Power Take-Off (PTO) — — —

Synchronizer assemblies 150°C (302°F) Mainshaft drag 2-8 — 18-70

Thrust washers 150°C (302°F) Reverse lamp switch 20 — 177

Shaft bushings 150°C (302°F) Shift housing-to-case 23 17 —

Copyright  2007, Ford Motor Company

2008 F-250, 350, 450, 550 Super Duty, 7/2007

DESCRIPTION AND OPERATION

Copyright  2007, Ford Motor Company

DIAGNOSIS AND TESTING

Copyright  2007, Ford Motor Company

1. With the vehicle in NEUTRAL, position it on a

2. NOTE: Drain the transmission while the

6. Apply threadlock and sealer and install the fill

Copyright  2007, Ford Motor Company

Special Tool(s) All vehicles

Holding Fixture, Drive Pinion

2. NOTE: Index-mark the driveshaft to the flange.

Remover, Input Shaft Oil Seal

Four-Wheel Drive (4WD) vehicles

3. Remove the transfer case. For additional

Socket, Mainshaft Locknut (36

Copyright  2007, Ford Motor Company

4. Apply threadlock to the threads of the

1. Using the Output Shaft Oil Seal Installer (4x4),

2008 F-250, 350, 450, 550 Super Duty, 7/2007

8. For other driveshaft configurations, refer to

2008 F-250, 350, 450, 550 Super Duty, 7/2007

1. Remove the shift lever boot and position it

1. Install the lower gearshift lever and gearshift

3. Remove the 2 screws and the lower shift lever

Copyright  2007, Ford Motor Company

3. Install the lower shift lever boot and the 2

2008 F-250, 350, 450, 550 Super Duty, 7/2007

REMOVAL AND INSTALLATION

6. Remove the 2 screws that attach the bezel and

3. Remove the 2 screws and the lower shift lever

Copyright  2007, Ford Motor Company

8. With the vehicle in NEUTRAL, position it on a

9. If the transmission is being disassembled, drain

10. Remove the exhaust Y-pipe. For additional

12. Remove the skid plate, if equipped.

16. Remove any Power Take-Off (PTO) equipment,

17. Using the Transmission Jack, support the

14. NOTE: Index-mark the driveshaft to the flange.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

22. Disconnect the wiring harness from the

21. Disconnect the reverse lamp switch electrical

2008 F-250, 350, 450, 550 Super Duty, 7/2007

26. Remove the 7 transmission-to-engine bolts.

27. Remove the transmission.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

REMOVAL AND INSTALLATION

6. Working under the vehicle, remove the 2 bolts

3. Remove the 2 screws and the lower shift lever

Copyright  2007, Ford Motor Company

14. Remove the 4 RH crossmember nuts.

7. With the vehicle in NEUTRAL, position it on a

8. If the transmission is being disassembled, drain

9. Remove the skid plate, if equipped.

10. Remove the transfer case, if equipped. For

11. NOTE: Index-mark the driveshaft to the flange.

16. Disconnect the wire harness from the

17. Remove the 2 transmission mount nuts and the