M5R1 Final assembly assistance needed

[jpark6491]

I am nearing completion of a rebuild of my transmission but I am struggling to figure out the way the last few bits go back together. Any help is appreciated. The final gear on the counter shaft does not seem to seating properly. Also I am not sure where these 2 half moon washers go. Judging by the diagram I am looking at it doesn’t seem to fit right.

 

[85_Ranger4x4]

https://therangerstation.com/tech_library/pdf_documents/ford_m5od_manual_transmission_shop_manual.pdf

#8 page 21? (Printed page numbers are goofy)

 

[jpark6491]

https://therangerstation.com/tech_library/pdf_documents/ford_m5od_manual_transmission_shop_manual.pdf

#8 page 6?

I already have the service manual...#18 is the split washer and although I see where it’s supposed to go it’s not fitting correctly.

 

[Transman304]

Looks to be the 5th gear hub #16 (synchronizer) might be installed upside down. Hard to tell from picture.

 

[BlackBII]

Yeah something isn't right.

This is what it should look like; notice how the gears mesh

Here's a page from my manual that shows where the split washer(#14) goes.

 

[jpark6491]

Thank you for the tips guys. When I get home today I will try to flip the hub assembly around and see if that works.

 

[jpark6491]

So I flipped the hub assembly and things to fit much better but I am still confused about these split washers. Are they supposed to fit flush against the hub assembly and slide underneath the row of teeth? If that is the case they don’t want to do that at all. 2nd picture is actually without the split washers at all

 

[Transman304]

There is a thrust washer with one side cut out that goes over the split rings. Post some pictures of your parts left to Install.

 

[jpark6491]

I see where the split washers would fit right inside the thrust washer but the gear will not sit flush with them for some reason

 

[Transman304]

You probably should take everything of the counter shaft and start over. Make sure the ball that holds the bearing race didn’t fall out and holding things up. Swap the bronze syncros you may have them flopped.

 

[jpark6491]

I’m really at a loss here guys. Everything seems to fit perfectly except for the split washer. I have all synchros and other parts to the end of the counter shaft in the correct position. Is it possible to maybe just grind a small part of each split washer so that it fits more easily?

 

[jpark6491]

The transmission is finally back together now! Grinding off one side of each of the split washers helped them to fit better for some reason, hopefully it doesn't hurt anything.

 

[alwaysFlOoReD]

Good luck.

 

[jpark6491]

Update: 5th gear is not engaging. It pops right back out of gear with a grinding noise when trying to shift.

Going to take the tail end apart and try again. Hopefully I can do this with the trans still in place.

Obviously grinding the split washers was not a great idea, but any insight on how exactly this would affect 5th gear? Or why perhaps 5th gear was not seating properly??

 

[BlackBII]

If you had to grind the split washers down to fit, it means that everything before them on the counter shaft (including 5th) isn't seated all the way or is assembled wrong. There should be room for the washers to fit. If not, something isn't right. I wish I could be of more help but it's hard to diagnose stuff like this over the internet.