Page 3 4 5

G-Force T5 Assembly (continued)

The output shaft assembly is carefully set into the case as shown. Note the plastic oil funnel insert has also been transferred to the end of the new countershaft.

A new bearing cone is pressed on to the input shaft. Note the pipe used to only apply pressure on the inner race. The bearing is pressed until it seats on the shaft shoulder.

Place the 15 individual bearing rollers into the end of the input shaft. Moly grease is used to hold them in position.

The thrust race, thrust bearing and spacer are placed on the front end of the output shaft.

Install the input shaft on the over the output shaft pilot. The input shaft must be rotated so the flat portion of the clutch tooth gear aligns with the counter shaft (opposite of disassembly in step 17.)

The 5th gear drive assembly goes on next. Install the 5th speed drive gear and blocking ring on the end of the counter shaft gear. This is followed by the 5th synchronizer and fork as shown.

Install the roll pin through the 5th shift fork and shift rail. Also install the synchronizer retainer and snap ring on the end of the counter shaft.

The case cover and shift fork assembly will go on next. After thorough cleaning, Bruce checks the forks and selector plates for damage. Normally a new set of fork pads (included in more rebuild kits) is all that is needed for a good rebuildable core.

Selector plates should be closely inspected for cracks at the corners of notches. Bruce prefers a snug fit between the selector plate and shift fork for crisp shifting. The notch can be tightened slightly by squeezing the plate with pliers or channel locks.

A new O-ring goes on the end of the shifter shaft.

With a bead of black silicone RTV around the mating surface, the case cover is positioned into place. The shift forks must engage the synchronizer collars. The synchronizers must be in the neutral position. Install the top cover bolts and torque to 10 lb-ft.

Install the speedo gear clip onto the output shaft, then slide on the speedometer drive gear, followed by the snap ring. We're using a 7 tooth (yellow) drive gear (refer to step 8 for more on speedo gear selection.)

With a new tailshaft bushing and seal (see side bar "T5 Rebuild Tips") installed, the tailshaft is prepared for attachment to the transmission case. Run a bead of black RTV around the mating surface.

The top two tail shaft bolts should be installed with Teflon paste sealer to prevent leaking as they enter the main case.

We'll install a new steel bearing retainer rather than the stock aluminum unit. Steel will ensure smoother throwout bearing operation. Note the narrow slot is oriented up. Install the retainer without shims or RTV until preload is checked and set (step 60)

Setting preload. Give the input shaft a good smack with a mallet to ensure the gears and bearings in the case are fully seated. With a dial indicator placed on the output shaft, push inward on the input shaft. Add .003 in. to .005 in. to the measurement on the dial indicator to achieve the appropriate shim to place under the bearing retainer.

Like an artist, Bruce "signs" each T5 which comes through his shop for rebuilding. Modern Driveline is the only rebuilder we know of who'll back their rebuild with a six month warranty against workmanship.

The rebuild Modern Driveline G-Force T5 is ready for abuse. We'll fill it with the recommended mixture of 2 parts G-Force lubricant and 1 quart Mobil 1 Synthetic ATF.




Page 3 4 5


T5 Rebuild Tips
Ford T5 tailshaft bushings (top) are nearly twice as long as the parts store replacements or as found in the rebuild kits. Obtain the Ford bushing as it likely offers better support for the driveshaft yoke.

A variety of tail shaft seals are available; ranging from a tall dust boot to nearly none at all. There is no performance difference, you might consider the larger boot for vehicles which see off road use.










































Bruce Coture's Modern Driveline
San Jose, CA
(408) 265-0741

G-Force Transmissions
150 N. Grant Street
Cleona, PA 17042
(717) 202-8367

Transmission Technologies Corp.
(800) 401-9866


Tech Archives Project Cars Readers Cars Feature Cars