• Welcome Visitor! Please take a few seconds and Register for our forum. Even if you don't want to post, you can still 'Like' the posts that you read.

M5R1 Final assembly assistance needed


jpark6491

Member
Supporting Member
Joined
Feb 25, 2019
Messages
62
Reaction score
5
Points
8
Location
Illinois
Vehicle Year
1999
Make / Model
Ford
Engine Size
2.5 L4
Transmission
Manual
2WD / 4WD
2WD
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.
 

Attachments



Rock Auto 5% Discount Code: 4FF3E9EEA14805 Expires: October 1st, 2020

jpark6491

Member
Supporting Member
Joined
Feb 25, 2019
Messages
62
Reaction score
5
Points
8
Location
Illinois
Vehicle Year
1999
Make / Model
Ford
Engine Size
2.5 L4
Transmission
Manual
2WD / 4WD
2WD

Transman304

Active member
Joined
Oct 3, 2014
Messages
251
Reaction score
26
Points
28
Location
Morgantown WV
Vehicle Year
2000
Make / Model
Honda
Engine Size
3.0
Transmission
Automatic
My credo
If you can’t fix it with a hammer, you have an electrical problem
Looks to be the 5th gear hub #16 (synchronizer) might be installed upside down. Hard to tell from picture.CA935FE1-836F-4888-9EC4-513DB2551569.jpeg
 

BlackBII

Ranger Custom
Article Contributor
OTOTM Winner
TRS Banner 2010-2011
Joined
Aug 14, 2007
Messages
7,513
Reaction score
233
Points
63
Location
UT
Vehicle Year
1989
Make / Model
Ford
Engine Type
4.0 V6
Transmission
Manual
2WD / 4WD
4WD
Total Lift
5
Tire Size
33
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.

 
Last edited:

jpark6491

Member
Supporting Member
Joined
Feb 25, 2019
Messages
62
Reaction score
5
Points
8
Location
Illinois
Vehicle Year
1999
Make / Model
Ford
Engine Size
2.5 L4
Transmission
Manual
2WD / 4WD
2WD
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

Member
Supporting Member
Joined
Feb 25, 2019
Messages
62
Reaction score
5
Points
8
Location
Illinois
Vehicle Year
1999
Make / Model
Ford
Engine Size
2.5 L4
Transmission
Manual
2WD / 4WD
2WD
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
 

Attachments

Transman304

Active member
Joined
Oct 3, 2014
Messages
251
Reaction score
26
Points
28
Location
Morgantown WV
Vehicle Year
2000
Make / Model
Honda
Engine Size
3.0
Transmission
Automatic
My credo
If you can’t fix it with a hammer, you have an electrical problem
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

Member
Supporting Member
Joined
Feb 25, 2019
Messages
62
Reaction score
5
Points
8
Location
Illinois
Vehicle Year
1999
Make / Model
Ford
Engine Size
2.5 L4
Transmission
Manual
2WD / 4WD
2WD
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
 

Attachments

Transman304

Active member
Joined
Oct 3, 2014
Messages
251
Reaction score
26
Points
28
Location
Morgantown WV
Vehicle Year
2000
Make / Model
Honda
Engine Size
3.0
Transmission
Automatic
My credo
If you can’t fix it with a hammer, you have an electrical problem
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

Member
Supporting Member
Joined
Feb 25, 2019
Messages
62
Reaction score
5
Points
8
Location
Illinois
Vehicle Year
1999
Make / Model
Ford
Engine Size
2.5 L4
Transmission
Manual
2WD / 4WD
2WD
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?
 
Last edited:

jpark6491

Member
Supporting Member
Joined
Feb 25, 2019
Messages
62
Reaction score
5
Points
8
Location
Illinois
Vehicle Year
1999
Make / Model
Ford
Engine Size
2.5 L4
Transmission
Manual
2WD / 4WD
2WD
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

Forum Staff Member
Forum Moderator
TRS Banner 2012-2015
TRS 20th Anniversary
Joined
Apr 13, 2009
Messages
10,571
Reaction score
1,464
Points
113
Location
Red Deer, Canada
Vehicle Year
'91, '94, '80
Make / Model
Ford, GMC
Engine Size
4.0,4.0,350
Transmission
Manual

jpark6491

Member
Supporting Member
Joined
Feb 25, 2019
Messages
62
Reaction score
5
Points
8
Location
Illinois
Vehicle Year
1999
Make / Model
Ford
Engine Size
2.5 L4
Transmission
Manual
2WD / 4WD
2WD
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

Ranger Custom
Article Contributor
OTOTM Winner
TRS Banner 2010-2011
Joined
Aug 14, 2007
Messages
7,513
Reaction score
233
Points
63
Location
UT
Vehicle Year
1989
Make / Model
Ford
Engine Type
4.0 V6
Transmission
Manual
2WD / 4WD
4WD
Total Lift
5
Tire Size
33
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.
 


Top