Gathering information to rebuild my transmission.

[rebelrider.mike]

Well, where to start? I have a 99 Ranger with a noisy transmission. I've had it in to the mechanic, who figures it has some bad bearings. He did change the transmission fluid, but warned me beforehand that it would probably make no difference. It didn't. But there were no alarming things coming out of the transmission. Just old fluid.

The transmission functions perfectly. While if 5th gear, it makes a terribly loud noise who's pitch depends on the speed of the truck. Also louder when accelerating. 3rd gear has also started making a moderately loud noise. Same behavior. I've also been told that the clutch slave cylinder is leaking, though I've not seen the fluid go down yet.

Normally I'd say "fix it, fix it fix it; shut up and take my money!", but in this case, it would cost over $6k, and I don't have that much to spare. Oh, he also said that it should be ok to drive the truck until I can't stand the noise anymore. In the meantime, I've put some medical restrictions on the truck: no hauling or towing heavy objects, no long distance travels, no more using 5th gear, and don't go over 60mph.

I normally stick to small engines. Motorcycles, lawn mowers, that sort of thing. But that price tag though! Makes me sorely tempted to try to tackle this myself. I've done lawnmower transmissions. Automotive manual transmissions are larger with extra parts like syncros, but otherwise pretty similar, yes?

So here's what I think I know so far:
I have a manual 5 speed with electric selection between 2WD, 4-Hi, and 4-Low. I think that makes the transmission an M5OD.
It's a 99, so it's also an M5OD-R2, or M5R2? I'm a bit confused on that one.
Removal seems pretty strait-forward. Disconnect the battery and starter motor, electrical wires, hydraulic clutch line. Remove a cross-member, and a mounting bracket, remove the drive shafts, and the 4WD gear box (I forgot what that's called), remove the shifter arm in the cab, and remove the bolts from the bell housing. Let gravity do the rest.

I've collected a few things from around the internet that I think pertain to the project:
https://www.therangerstation.com/te...ford_m5od_manual_transmission_shop_manual.pdf
https://transpartswarehouse.com/catalogsearch/result/index/?cat=9641&q=standard ford m5r2&p=2
https://www.therangerstation.com/tech_library/pdf_documents/ToyoKoygoMazda.pdf

Have I got anything right so far?

I'm thinking I'll buy a shop manual for the truck. Maybe I can buy one specifically for rebuilding the transmission? I really like the ones with pictures. I'm not afraid to read articles, so if anyone has useful links to share, I'd love to see them! I probably won't be starting this for another couple of months, so plenty of time to gather info.

 

[pjtoledo]

are you in the rust belt?
we "rusties" often find getting the exhaust system out of the way is worse than the actual transmission work.
putting it back in is not fun either.
by the way, Y-pipes are no longer available. separating the Y pipe from the cats can be a point of no return that may require welding & fabrication to fix.

 

[RobbieD]

I've put some medical restrictions on the truck

I like that.


Do yourself a favor; buy the shop manual. I like paper manuals myself (either for just nostalgia, or in case of a TP shortage I guess), and I'd suggest watching eBay, as the manual sets (usually they are two big books) come up very reasonably if you're patient or lucky.

The electrical manual, the EVTM, is also well worth having.

The Ford manuals I have, through 1994, cover the transmissions pretty well. 1999 should be the same deal.

 

[600$04Ranger]

Find a transmission jack if you can. It makes the job of lining up the bell housing bolts and the input shaft much easier. I took my manual transmission apart to rebuild it once. It was quite challenging. Requires a pretty good hydraulic press for the bearings. I was able to do this at a friends machine shop. As for disassembly of the transmission it's helpful to take many pictures and have a large table or two where you can lay out your parts in the order they are removed so you can work backwards to reassemble. Definitely agree with the previous comment about your exhaust. Make sure and spray all fasteners with penetrant a day or two before removal. The job of removing and reinstalling the transmission usually takes me about 8 hours doing it without a lift and alone without anyones help. Good luck and enjoy!

 

[rebelrider.mike]

I live in Washington. We generally use sand rather than salt in the winter time. But it does rain here a lot, and I don't have a garage. So we'll see what happens. I forgot about the exhaust. If it defeats me, I can go to the muffler place down the road. The fellow there will weld up whatever is needed.

I definitely want a shop manual. And a transmission jack. I've got a 25 year old son who can help, as well as a hydraulic press, and a few other gadgets that might make the job easier. I also don't mind building my own tools if I have to.

Documenting my projects is one of my hobbies. Also, I forget most of what I learn in a couple months, so I kind of have to. I'm happy to share here if you all are interested.

 

[SenorNoob]

Pretty close so far. Sounds like you have good idea of what you're getting into.

Just one thing. The Ranger transmission is an M5OD-R1. The R2 is the F150 version. If you want to just swap it, you have to get one from a 3.0 4x4. Similar in design but very little compatibility. (Shifter bushings maybe?)
Oh that 4WD gearbox is called a transfer case.

 

[rebelrider.mike]

I see! Good to know. I've been searching R1 vs. R2. The R1 is the light duty version and all the Rangers have them. So when I go to look for parts, I'll have to make sure they're for the 4x4 R1.

Transfer case! As I post more, you'll find I'm terrible with proper terminology. I try to take my time when I write though, to use the right words, but last night I was tired and just wanted to hit "post reply", LOL. Keep in mind that 2 days ago, I had no idea what transmission I had. It was always just "the transmission".

But I like learning new things, and I'm getting interested in opening this guy up. I'll have to arrange for an alternate vehicle for a while so I don't have to rush through things. I'm hearing that this guy takes ATF and not gear oil. I'll have to make sure I get the right kind.

What do you all think about the Chilton and Haynes shop manuals? Lots of those out there. I'm still looking for anything that sounds like "official Ford shop manual".

 

[Shran]

I messaged you with some stuff I have on file.

These are not super hard to rebuild but there are a lot of things to watch for.

 

[NakedDucks]

Wish you weren’t so far away. I’ve got 2. 3.0 M5OD’s the I will never use. They are 2nd, but in perfect working order so you’d only have to swap the mainshaft and rear housing and be good to go. You and I could do it in my garage in like an hour and a 1/2.

 

[scotts90ranger]

I've been in mine twice, first time my transmission mechanic buddy did the work while I was there helping, second time was a couple years ago (got a bad bearing the first time) and I did it myself but I've also done rebuilds on the trans in my Geo Tracker before myself and even gone through the manual in my F350 a couple times now...

Last time I did my M5OD I watched a youtube video or two for a refresher... The hardest part is getting the rear bearing off so you can get the 5/R parts out to get the output shaft out, I had to make extensions for a 2 jaw puller but was simple after that.

It sounds like it's just a bearing on the counter shaft or maybe the center bearing on the output shaft like on mine that made a HORRIBLE racket in 5th and a little whiny in 3rd, the inner race looked like a dang file...

 

[scotts90ranger]

Oh and if you do do it yourself you can get the rear nut off the shaft by locking it in two gears (once the shift tower is off it's easy, I think 2 and 3 works...) to keep the shaft from turning, take a chisel or something and unstake the nut in the groove then use a big adjustable wrench or pipe wrench... I've re used the nut before but they're available if you think of it when buying parts.

I didn't look at where you are in Washington but if you're up for a trip to Portland (believe me, I try to avoid it at all possible too...), Transmission Exchange is by the Moda Center and they will have anything you need, more expensive than getting an Ebay kit but it's supporting a local business and they do know their stuff...