2006 ford gt workshop manual - quality service manual

Installation

NOTE: Clean the clutch pressure plate and flywheel with a commercial alcohol-based solvent so surfaces arefree from oil film.

Do not use cleaners with a petroleum base. Do not immerse the clutch pressure plate in the solvent.

Using the special tool, position the clutch assembly on the flywheel.1.

NOTE: If reusing the clutch pressure plate, align the plate using the marks made during removal.

Install the pressure plate-to-flywheel bolts evenly in a star pattern. Tighten to 26 Nm (19 lb-ft).

2.

NOTE: Before installing the transmission, the input shaft must be cleaned and lightly lubricated withgrease.

Install the transmission. For additional information, refer to Section 308-03 .

3.

2006 Ford GT Workshop Manual

Clutch Disc and Pressure Plate 1243


Clutch Disc and Pressure Plate 1244

SECTION 308-01: Clutch 2006 Ford GT Workshop ManualREMOVAL AND INSTALLATION Procedure revision date: 10/04/2007

Pilot Bearing

Special Tool(s)

Puller with Slide Hammer308-001 (T58L-101-B)

Remove the clutch disc and the clutch pressure plate. For additional information, refer to Clutch Discand Pressure Plate in this section.

1.

Using the special tool, remove the pilot bearing from the crankshaft.2.

Installation

Insert the pilot bearing into the crankshaft.1.

Install the clutch disc and the clutch pressure plate.2.


Pilot Bearing 1245


Pilot Bearing 1246

SECTION 308-02: Clutch Controls 2006 Ford GT Workshop ManualSPECIFICATIONS Procedure revision date: 09/27/2005

General Specifications

Item SpecificationClutch SystemClutch control HydraulicSystem adjustment AutomaticClutch pedal type SuspendedFluid and LubricantMotorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1 ESA-M6C25-A

Torque Specifications

Description Nm lb-ft lb-inClutch slave cylinder bolts 11 8 —Clutch master cylinder bolts 20 15 —Knee bolster bolts 9 — 80


Pilot Bearing 1247

SECTION 308-02: Clutch Controls 2006 Ford GT Workshop ManualDESCRIPTION AND OPERATION Procedure revision date: 11/15/2005

Clutch Controls

Item Part Number Description1 7K500 Clutch system reservoir2 7K502 Clutch reservoir-to-clutch master cylinder supply tube3 7A843 Clutch master cylinder4 2450 Brake and clutch pedal and support assembly5 7T504 Hydraulic line6 — Bleeder screw (part of 7A564)7 7A564 Clutch slave cylinderThe clutch control system actuates the clutch system. When the clutch pedal is depressed, it pushes the clutchmaster cylinder plunger which transmits hydraulic pressure to the clutch slave cylinder. The clutch slavecylinder engages and compresses the clutch pressure plate diaphragm spring, releasing the pressure on theclutch disc which in turn disengages the transmission from the engine.

The clutch adjusts automatically to compensate for clutch disc wear.

The clutch pedal position (CPP) switch prevents the starter motor from engaging unless the clutch pedal isdepressed all the way to the floor. The switch plunger is contacted by the clutch pedal and extends as theclutch pedal is pressed. The clutch pedal position switch is electrically connected in line with the ignitionswitch and the starter motor relay coil.


Clutch Controls 1248

SECTION 308-02: Clutch Controls 2006 Ford GT Workshop ManualDIAGNOSIS AND TESTING Procedure revision date: 09/27/2005

Clutch Controls

Refer to Section 308-00 .



SECTION 308-02: Clutch Controls 2006 Ford GT Workshop ManualREMOVAL AND INSTALLATION Procedure revision date: 09/27/2005

Clutch Master Cylinder

Material

Item SpecificationMotorcraft High Performance DOT 3Motor Vehicle Brake FluidPM-1

ESA-M6C25-A

Using a suitable suction tool, drain the clutch reservoir.1.

Remove the lower instrument trim panel.2.

Remove the knee bolster.To install, tighten to 9 Nm (80 lb-in).•

3.

Remove the clutch master cylinder cotter pin and washer. Separate the clutch master cylinder from theclutch pedal.

Discard the cotter pin.•

4.

CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilledonto a painted or plastic surface, wash the surface with water immediately.

5.


Clutch Master Cylinder 1251

NOTE: Position a suitable container under the clutch master cylinder.

Loosen the clamp and disconnect the clutch reservoir supply tube.

Plug the tube and the clutch master cylinder.•

Remove the clip, then disconnect the clutch master hydraulic line.Plug the hydraulic line and the clutch master cylinder.•

6.

Remove the clutch master cylinder bolts, then the clutch master cylinder.To install, tighten to 20 Nm (15 lb-ft).•

7.

To install, reverse the removal procedure.Install a new cotter pin.• Bleed the clutch system. For additional information, refer to Section 308-00 .•

8.


Clutch Master Cylinder 1252

SECTION 308-02: Clutch Controls 2006 Ford GT Workshop ManualREMOVAL AND INSTALLATION Procedure revision date: 09/27/2005

Clutch Slave Cylinder

Removal and Installation

Remove the transmission. For additional information, refer to Section 308-03 .1.

NOTE: Inspect the clutch housing for traces of fluid. If brake fluid is visible, install a new clutchconcentric slave cylinder.

Remove the clutch concentric slave cylinder bolts, then the clutch concentric slave cylinder.

To install, tighten to 11 Nm (8 lb-ft).•

2.

Inspect the clutch concentric slave cylinder for the following:Worn or damaged boot• Leaking fluid• Worn or damaged bearing•

3.

To install, reverse the removal procedure.Bleed the clutch hydraulic system.•

4.


Clutch Slave Cylinder 1253

SECTION 308-03: Manual Transaxle/Transmission 2006 Ford GT Workshop ManualSPECIFICATIONS Procedure revision date: 02/26/2007

General Specifications

Item SpecificationLubricants and SealantsMotorcraft SAE 75W90 Premium Synthetic Transaxle Lubricant XT-75W90-QGT —Premium Long-Life Grease XG-1-C or equivalent ESA-M1C75-BTransmission fluid capacity 4 L (4 qts)Silicone Gasket and Sealant TA-30 WSE-M4G323-A4Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1 ESA-M6C25-AThreadlock and Sealer TA-25 WSK-M2G351-A5

Torque Specifications

Description Nm lb-ft lb-inTransmission-to-engine bolts 47 35 —Output shaft speed (OSS) sensor bolt 11 8 —Output flange bolts 30 22 —Drain plug 27 20 —Reverse lamp switch 27 20 —Fill plug 27 20 —Starter motor bolts 48 35 —Shift cable-to-transmission bracket bolts 26 19 —Transmission mount nut 200 148 —Muffler bracket bolts 25 18 —Starter terminal nut 9 — 80Lower pan bolts 7 — 62Upper crossmember bolts 27 20 —Transmission mount bolts 25 18 —Gearshift lever bracket bolts 25 18 —Gearshift control bolts 19 14 —Halfshaft hub nut 400 295 —Halfshaft bolts a — — —a Refer to the procedure in this section.



SECTION 308-03: Manual Transaxle/Transmission 2006 Ford GT Workshop ManualDESCRIPTION AND OPERATION Procedure revision date: 09/27/2005

Manual Transmission

The Ricardo 6-speed manual transmission features the following:

Six forward speeds and one reverse speed• Dual clutch• Gear ratios of:

1st 2.611♦ 2nd 1.708♦ 3rd 1.233♦ 4th 0.943♦ 5th 0.767♦ 6th 0.625♦ Reverse 3.135♦ Final drive 3.364♦

•

a shift interlock system prevents the engagement of more than one gear.• transmission gear cluster positioned behind the differential.• an aluminum main case and extension housing.• is only serviced as an assembly.•


Manual Transmission 1256

SECTION 308-03: Manual Transaxle/Transmission 2006 Ford GT Workshop ManualDIAGNOSIS AND TESTING Procedure revision date: 09/27/2005

Manual Transmission

Refer to Section 308-00 .


Manual Transmission 1257

SECTION 308-03: Manual Transaxle/Transmission 2006 Ford GT Workshop ManualGENERAL PROCEDURES Procedure revision date: 09/27/2005

Transmission Draining and Filling

Material

Item SpecificationMotorcraft SAE 75W90 PremiumSynthetic Transaxle LubricantXT-75W90-QGT

—

Item Part Number Description1 7010 Drain plug2 — Washer (copper) (part of 7010)3 7010 Fill plug

Remove the drain plug and drain the transmission.Position a suitable drain pan under the transmission.•

1.

Clean the drain plug, the drain plug magnet and threads. Remove and carefully clean the drain plugstrainer. Check the O-ring for damage. Install a new O-ring as necessary.

2.

Install the drain plug.Tighten to 27 Nm (20 lb-ft).•

3.

NOTE: Before removing, clean the area around the filler plug.

Remove the filler plug.

4.

Using a suitable oil suction gun, fill the transmission to the correct level with the specified fluid.Transmission capacity is 4.0 liters (4 quarts).• Fluid level should be at the bottom of the fill plug opening.•

5.

Install the filler plug.Tighten to 27 Nm (20 lb-ft).•

6.


Transmission Draining and Filling 1258


Transmission Draining and Filling 1259

SECTION 308-03: Manual Transaxle/Transmission 2006 Ford GT Workshop ManualIN-VEHICLE REPAIR Procedure revision date: 03/10/2006

Halfshaft Seal

Special Tool(s)

Installer, Output Shaft Seal308-600

Material

Item SpecificationMotorcraft SAE 75W90 PremiumSynthetic Transaxle LubricantXT-75W90-QGT

—

Threadlock and SealerTA-25

WSK-M2G351-A5

Item Part Number Description1 71138 Output flange bolt (2 required) (M8X25)2 7B368 Output shaft washer3 4851 Output shaft flange4 1177 Halfshaft sealRemoval and Installation

Remove the 6 halfshaft bolts and the 3 plate washers. Disconnect the halfshaft from the transmission.Position the halfshaft aside.

Discard the bolts.• Using mechanic's wire, support the halfshaft.•

1.

NOTE: Apply Threadlock and Sealer to the bolt threads prior to installation.

Remove the 2 output flange bolts.

2.


Halfshaft Seal 1260

Tighten the bolts in 2 stages:Stage 1: Tighten both bolts to 20 Nm (15 lb-ft).♦ Stage 2: Tighten both bolts to 30 Nm (22 lb-ft).♦

•

Remove the output shaft washer.3.

Remove the output shaft flange.4.

Using a suitable seal remover, carefully remove the halfshaft seal. Make sure not to damage the sealbore.

5.

To install, reverse the removal procedure.Using the special tool, install a new halfshaft seal.• Always install a new halfshaft hub nut.• Tighten the new halfshaft bolts in 5 stages.

Stage 1: Install the new halfshaft nut.Tighten to 400 Nm (295 lb-ft).♦

♦

Stage 2: Alternately tighten halfshaft bolts, in a star pattern, as shown to 40 Nm (30lb-ft).

♦

Stage 3: Loosen halfshaft bolts one full turn one at a time. Tighten to 28 Nm (21lb-ft) then tighten an additional 90 degrees. Repeat for the remaining halfshaft boltsin a circular pattern.

♦

Stage 4: Drive the vehicle for at least 3 miles.♦ Stage 5: Loosen the halfshaft hub nut 1/2 turn and retighten.

Tighten to 400 Nm (295 lb-ft).♦ ♦

•

Fill the transmission to specification, as necessary.•

6.


Halfshaft Seal 1261


Gearshift Lever

Item Part Number Description1 7J170 Retainer clip2 7J170 Cable clip3 7E395-A Crossgate cable4 7E395-B Into gear cable5 N804178-S309 Gearshift lever bracket nut6 391797-S40 Washer7 7K387 Gearshift lever bracket assemblyRemoval and Installation

Remove the center console. For additional information, refer to Section 501-12 .1.

Remove the retainer and cable clips, then disconnect the shift cables from the gearshift lever and thegearshift lever bracket.

2.

Remove the gearshift lever bracket nuts, then the gearshift lever.To install, tighten to 25 Nm (18 lb-ft).•

3.

To install, reverse the removal procedure.4.

If necessary, adjust the gearshift cables. For additional information, refer to Section 308-00 .5.


Gearshift Lever 1262


Gearshift Lever 1263


Gearshift Cables

Item Part Number Description1 7K387 Gearshift lever2 N605803-S Gearshift lever bracket3 7E395-B Into gear lever cable4 7E395-A Crossgate cable5 7E046 Gearshift lever cable bracket (engine)6 70440 Transmission bracket7 70405 Into gear lever (part of gearshift assembly)8 69633 Crossgate leverRemoval and Installation

Remove the center console. For additional information, refer to Section 501-12 .1.

Remove the retainer and cable clips, then disconnect the shift cables from the gearshift levers and thegearshift bracket.

2.

CAUTION: The engine cover is sealed with a 6-mm (0.23-in) bead of butyl-covered foam.Use care when removing the panel and cleaning the butyl, as it can stain interior trim panelsand seats.

Remove the bolts and the engine cover.

Using a plastic or wooden scraping tool and mineral spirits, clean the butyl from the enginecover and the body mating surface.

•

Using a mild soap and water solution, spray the gearshift cable boot to aid in cable removal.•

3.

Remove the shift cable bolt and the shift cables from the shift cable bracket.To install, tighten to 11 Nm (8 lb-ft).•

4.


Gearshift Cables 1264

Remove the retainer clips and disconnect the shift cables from the gearshift lever and the crossgatelever.

5.

Remove cable clips from the cable bracket at the transmission.6.

NOTE: Do not damage the O-ring on the dust boot.

Remove the shift cables from the cable bracket.

Remove the shift cable nut.To install, tighten until the cable clips can be seated and fully installed. Do notdamage the isolators.

♦ 1.

Remove the shift cables.2.

7.

NOTE: The shift cables go through the bulkhead grommet and between the left cylinder head andlower intake manifold.

NOTE: During installation, route the into gear cable (marked with yellow band) on top of thecrossgate (black) cable at the engine shift cable bracket. The into gear cable (yellow band) crosses thecrossgate (black) cable.

Remove the gearshift cables.

8.



To install, reverse the removal procedure.Apply butyl around the engine cover mating surface. Apply the butyl-covered foam betweenthe bolt holes and the inside lip of the opening.

• 9.

Adjust the gearshift cables. For additional information, refer to Section 308-00 .10.




Input Shaft Seal

Special Tool(s)

Installer, Input Shaft308-601

Item Part Number Description1 7A283 Input shaft sealRemoval and Installation

Remove the transmission. For additional information, refer to Transmission in the Removal portion ofthis section.

1.

Remove the clutch slave cylinder. For additional information, refer to Section 308-02 .2.

Using a suitable seal remover, remove the input shaft seal. Make sure not to damage the seal bore.3.

Using the special tool, install the input shaft seal.4.

Install the clutch slave cylinder.5.

Install the transmission. For additional information, refer to Transmission in the Installation portion ofthis section.

6.


Input Shaft Seal 1267


Input Shaft Seal 1268


Output Shaft Speed (OSS) Sensor

Item Part Number Description1 W700275-S303 Output shaft speed (OSS) sensor bolt2 7H103 OSS sensorRemoval and Installation

Disconnect the OSS sensor electrical connector.1.

Remove the OSS sensor bolt.To install, tighten to 11 Nm (8 lb-ft).•

2.

Remove the OSS sensor.3.

To install, reverse the removal procedure.4.


Output Shaft Speed (OSS) Sensor 1269

SECTION 308-03: Manual Transaxle/Transmission 2006 Ford GT Workshop ManualREMOVAL Procedure revision date: 02/26/2007

Transmission

Special Tool(s)

Spreader Bar303-D089 (D93P-6001-A3 or equivalent

Lifting Eyes303-D030 (D81L-6001-D) or equivalent

Item Part Number Description1 7003 Transmission assembly2 N605803-S Transmission bolt (8 required)

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section100-02 .

1.

Disconnect the battery. For additional information, refer to Section 414-01 .2.

NOTE: An assistant will be needed to remove the deck lid.

Remove the deck lid.

Disconnect the electrical connectors.• Disconnect the deck lid lift pistons.• Remove the 4 deck lid bolts, and carefully remove the deck lid.•

3.

Remove the air cleaner assembly.Disconnect the mass air flow (MAF) sensor electrical connector.•

4.


Transmission 1270

Loosen the clamp and disconnect the air cleaner outlet tube from the air cleaner.• Remove the 2 air cleaner bolts.•

Remove the rear lower pan bolts and the rear lower pan.5.

Remove the 12 rear lower valance bolts and the rear lower valance.6.

Disconnect the starter motor electrical connectors.7.

Remove the 3 lower transmission-to-engine bolts.8.

Lower the vehicle.9.

Disconnect the heated oxygen sensor (HO2S) electrical connectors.10.

Remove the muffler assembly. For additional information, refer to Section 309-00 .11.

Remove the 3 bolts and the exhaust heat shield.12.

Remove the shift cable retaining clips, then disconnect the shift cables from the shift arms.13.

Remove the parking brake bezel.14.


Transmission 1271

2006 ford gt workshop manual - quality service manual

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