Mechanics

HOW CAN I TEARDOWN MY 5SPEED MANUAL GEARBOX?

1997 Ford Probe • 130,000 miles

What are the correct / perfect steps to follow in order to teardown the gearbox, i'm running on a limited budget i' planning to do it myself in order to take it to a specialist for repair,
Would be too much appreciated if anybody can provide detailed list for what remove first, second.
Thank you
Avatar
Mbarizia
January 18, 2012.



OVERHAUL - M5 MANUAL TRANSMISSION -1997 Ford Probe GT
Page 1 of 4
COMPONENT DISASSEMBLY & REASSEMBLY

OUTPUT SHAFT

NOTE: All components should be marked for reassembly reference when removed from output shaft. If bearing cone(s) are removed, replace with
NEW bearing cone(s).
Disassembly

1.
Before disassembly, check clearance between 1st gear and differential drive gear and between 2nd gear and 3rd gear. Refer to the OUTPUT SHAFT GEAR CLEARANCE table. If clearance is
above maximum, check gear and synchronizer contact surfaces. Replace any worn or damaged parts.
Using Shaft Protector (D80L-625-4) and Puller Attachment (D84L-1123-A), press off bearing cone (4th gear end) if necessary. Ensure output shaft is prevented from falling when bearing is
pressed off. Synchronizer rings are not interchangeable. Keep them in order they were removed. See Fig. 4.
Press off 4th gear and remove retaining ring. Slide synchronizer down to create gap to fit adapter plate. Press off 3rd and 2nd gears. Remove synchronizer ring and retaining ring. See Fig. 4.
Using shaft protector and seal plate, remove synchronizer hub, synchronizer ring and 1st gear. Press off bearing cone (1st gear end) if necessary. Remove synchronizer springs and keys from
synchronizer hub. Remove synchronizer hub from sleeve. For component cleaning and inspection, see step 5) under CLEANING & INSPECTION.
2.
3.
4.
Fig. 4: Exploded View Of Output Shaft Courtesy of FORD MOTOR CO.
Reassembly

1.
Slide synchronizer hub into synchronizer hub sleeve. Install synchronizer keys and springs. When installing synchronizer ring and synchronizer hub, align synchronizer ring groove and key. See
Fig. 5.
Using shaft protector, bearing cone replacer and installing plate, press bearing cone on 1st gear end. See Fig. 4. Using shaft protector, bearing installing plate and bearing cone replacer, press on
1st gear, synchronizer ring and synchronizer hub.
3. Ensure synchronizer hub oil groove faces away from 1st gear. Install retaining ring and synchronizer ring. Install 2nd and 3rd gears. Install retaining ring and 4th gear. Press on bearing
cone (4th gear end). Check assembled clearances. See OUTPUT SHAFT GEAR CLEARANCE table. If clearance is not within specification, reassemble output shaft.
2.
OUTPUT SHAFT GEAR CLEARANCE
Standard Clearance In. (Mm)
.002-.011 (.05-.28).007-.018 (.18-.46)
Maximum Clearance In. (Mm)
.013 (.33).020 (.51)
Application
1st Gear-To-Differential Drive Gear 2nd Gear-To-3rd Gear

1/18/2012
OVERHAUL - M5 MANUAL TRANSMISSION -1997 Ford Probe GT
Page 2 of 4
Fig. 5: Aligning Synchronizer Ring & Key Courtesy of FORD MOTOR CO.
INPUT SHAFT

NOTE: All components should be marked for reassembly reference when
removed from input shaft. If bearing cone(s) are removed, replace with NEW bearing cone(s).
Disassembly

1.
Before disassembly, check clearance between 2nd gear and 3rd gear and between 4th gear and 4th gear bearing. See INPUT SHAFT GEAR CLEARANCE table. If clearance is above maximum,
check gear, bearing and synchronizer contact surfaces. Replace any worn or damaged parts. Using Shaft Protector (D80L-625-4) and Puller Attachment (D84L-1123-A), press off bearing
cone and 4th gear (if necessary). Ensure input shaft is prevented from falling when bearing is removed.
Remove 4th gear synchronizer ring and retaining ring. See Fig. 6
bearing puller attachment, press off synchronizer hub, synchronizer ring and 3rd gear.
Press off bearing cone (3rd gear end) if necessary. Remove synchronizer springs and keys from synchronizer hub. Remove synchronizer hub from sleeve. For component cleaning and inspection,
see step 7) under CLEANING & INSPECTION.
2.
3.
. Using shaft protector and
4.
Reassembly

1.
Lubricate bearing bore and press on bearing cone (3rd gear end). Slide synchronizer hub into sleeve. Install synchronizer keys and springs. When installing synchronizer ring and synchronizer
hub, align synchronizer ring groove and key. See Fig. 5.
Using shaft protector, bearing plate and cone replacer, press on 3rd gear, synchronizer ring and synchronizer hub. Install retaining ring. Using shaft protector, bearing plate and cone replacer,
press on synchronizer ring, 4th gear and bearing cone. Check assembled clearances. See INPUT SHAFT GEAR CLEARANCE table. If clearance is not within specification, reassemble input
shaft.
2.
INPUT SHAFT GEAR CLEARANCE Application
2nd Gear-To-3rd Gear
4th Gear-To-4th Gear Bearing
Standard: In. (Mm).002-.007 (.05-.20)
.007-.015 (.20-.37)
Maximum: In. (Mm).010 (.25)
.017 (.42)
Fig. 6: Exploded View Of Input Shaft Courtesy of FORD MOTOR CO.
SYNCHRONIZER ASSEMBLIES

NOTE: Before disassembling synchronizer, mark sleeve and hub with index marks for reassembly reference. Synchronizer components are matched

1/18/2012
OVERHAUL - M5 MANUAL TRANSMISSION -1997 Ford Probe GT
Page 3 of 4
at factory and should not be interchanged.
Disassembly & Reassembly

1.
Note position of index marks. Remove springs from hub with small screwdriver. DO NOT compress springs any more than necessary. Slide hub and sleeve apart. Remove hub inserts. 1st-
2nd hub inserts are not interchangeable with other synchronizers. See Fig. 7. For cleaning and inspection of components, see CLEANING & INSPECTION
reverse disassembly procedure.
2.
. To assemble,
Fig. 7: Identifying Synchronizer Inserts Courtesy of FORD MOTOR CO.
MAIN SHIFT-CONTROL SHAFT

Disassembly

1.
Ensure shift forks are in neutral position by aligning selector interlock sleeve and selector arm. Rotate 3rd-4th shift fork away from 1st-2nd shift fork. Slide 3rd-4th shift fork and selector arm off
shift rail.
Remove and discard selector interlock sleeve roll pin. Remove selector interlock sleeve and 1st- 2nd shift fork. Remove and discard selector lever arm roll pin and remove selector lever arm from
shift rail.
2.
Reassembly

Install selector lever arm and NEW roll pin onto shift rail. Install 1st-2nd shift fork and selector interlock sleeve. Press NEW roll pin into interlock sleeve and shift rail. Install 3rd-4th shift fork and selector arm.
Rotate 3rd-4th shift fork to neutral position.
DIFFERENTIAL ASSEMBLY

NOTE: If bearing cone(s) are removed, replace with NEW bearing cone(s).
Disassembly

Prior to disassembly, check pinion gear backlash. See step 4) under CLEANING & INSPECTION. Remove roll pin and pinion shaft. Remove pinions and thrust washers by rotating
out of case. See Fig. 8.
Remove side gears and thrust washers. Using gear puller, step plate, puller attachment and legs from puller set, remove bearing cone from speedometer drive gear end of differential (if
necessary). Remove speedometer drive gear. Using puller and step plate, remove bearing cone from ring gear end of differential (if necessary).
1.
2.
Reassembly

1/18/2012
OVERHAUL - M5 MANUAL TRANSMISSION -1997 Ford Probe GT
Page 4 of 4
1.
Install speedometer drive gear and bearing cone using either a driver handle or a press and a cone replacer. Install bearing cone on ring gear end of differential.
Install thrust washers and pinions. Install pinion shaft. Install roll pin. Crimp pin to prevent pin from coming out of gear case. Install thrust washers and side gears.
2.
Fig. 8: Exploded View Of Differential Assembly Courtesy of FORD MOTOR CO.

1/18/2012


Rivermikerat
Jan 18, 2012.