M5OD-R2 Rebuild Help...

[shr3dd3r 09]

I am in desperate need of rebuilding my 4x4 M5ODR-2 manual transmission, but would like to do it myself if at all possible...

Does anyone know where I might find as much info as possible on doing this (other threads, others who have rebuilt this same tranny, etc.)? Or even find a rebuild kit for one? I know for a fact my transmission has at least one broken gear tooth and several other problems based on the shear amount of noise it makes.

I'd rather make some attempt at rebuilding it before I go and spend thousands on having someone else do it. At the very least I could get it taken apart on my own...

 

[adsm08]

Rebuilding an M5OD is pretty simple. Worst part is that you need a press to get the gears off the shafts.

 

[wizkid00104]

I got my parts from these guys: http://transpartswarehouse.com/
http://transpartswarehouse.com/index.php/standard/ford/m5r2.html

They were very helpful. And I agree with ADSM08, pretty easy and a press is needed. The adapters for tapping and pressing bearings and seals is very helpful too.

Here is a photo gallery of a R1 disassembly: http://s128.photobucket.com/user/Villanmotorsports/library/doubler/Trans Teardown?sort=3&page=1

I used a repair guide on a CD that my uncle had at the shop he worked at. Chilton or Haynes may cover it too.

 

[shr3dd3r 09]

I have a Ford CD that covers the disassembly of the M5R2, but I was looking for some first hand experience as well. What I have should get me started.

wizkid00104: Thanks so much for the link to the rebuild kits. I believe I can do the work myself if I take my time. I do have plenty of it since I'm completely overhauling the entire truck.... New engine, wiring harness, sanding and painting the frame, shocks, gears, etc. on and on...

 

[wizkid00104]

One other tip I can add. There are spring loaded collars that lock in the gears when you shift. Be VERY careful when disassembling to not take them apart (or have them accidentally fall apart) they can be a pain in the ass to put back together. Take a few photos of them so you can reassembly them easier if need be.

Transparts Warehouse had a very friendly staff when I used them. I needed 2 extra synchros because there were variations in the tranny. If you call them, they should be able to tell you of any issues you may run into like that.

Did you originally do the swap in the truck?

 

[shr3dd3r 09]

Yes I did. But I ended up with some bad luck with my transmission. It seemed I got one that had already seen its better days.

 

[shr3dd3r 09]

I think there is a broken gear tooth on the countershaft. It makes a horrible ticking noise in every gear except 4th when I decelerate. Noise goes away with clutch depressed. Also it makes a horrendous grinding noise while in neutral, but the slave, clutch, pilot bearing, flywheel, and everything are brand new. It's in bad shape.

In any case the truck has become my long term project for complete overhaul. So I plan on it being next to brand new by the time I'm done with it.

 

[wizkid00104]

I was getting a slight grinding noise in mine. It turned out that the shifter bushing dry rotted and fell into the transmission and blocked one of the oil channels. That was it. All my synchros were fine (2nd was a little worn) and the bearings didn't have any play. But I replaced them all since I had it apart. I used AMSOIL ATF when I refilled the tranny. I use their fluid in everything now. Its pricey, but its excellent quality and it lasts.

 

[shr3dd3r 09]

Yeah, maybe that's the source of the grinding. Or the input shaft bearing. I'll have to see when I take it apart. But I do know for a fact there is at least one broken gear tooth... I saw one fall out last time I drained the fluid.