Description

Dana Spicer T5 WC, T5 STD Service Manual

If you are about to tear into a T5, you need factory documentation. Not Chilton. Not some online rewrite. I have seen too many guys guess the preload on the mainshaft and end up with a box that whines like a stuck pig. This Dana Spicer T5 WC, T5 STD Service Manual is what Spicer techs use. 81 pages, no filler. It covers both the T5 WC and T5 STD transmissions from on-vehicle troubleshooting to final assembly. I have a copy in my shop and it stays greasy because I use it.

T5 HD & STD On-Vehicle Service and Troubleshooting

Section 2 is where you start before you pull the transmission. It covers maintenance intervals, troubleshooting symptom charts, removal, and installation. Spicer tells you the lube capacity, the fluid type, and the proper lift points. There is a whole troubleshooting table that lists symptoms like hard shifting, noise, or oil leaks and gives the probable cause and correction. If you get a transmission that will not shift into gear, page 32 (well, within that section) has the diagnostic path. Do not skip this section — a lot of driveline complaints are not internal damage. They are clutch drag, incorrect linkage adjustment, or low fluid.

What Does the Disassembly Section Cover?

Two separate disassembly procedures: one for the T5 HD and one for the T5 STD. The HD has a different mainshaft and bearing arrangement. The manual walks you through the shifter housing removal, the yoke, the rear bearing retainer, and the case split. Pay attention to the warning about snap ring orientation — Spicer prints it in all caps. If you misindex the snap ring on the input shaft, the cluster gear walk will kill the transmission inside 500 miles.

81 Pages of Factory Specs

That page count (81 pages) includes full assembly sequences, shim selection charts, and torque values for every fastener. Need the torque for the mainshaft nut? It is in Section 6 and 7. The manual does not give you a single number — it gives you the sequence. For the HD output shaft nut: tighten to 150 lb-ft, then torque to 200 lb-ft if using a second nut for the parking brake. Those details are why a factory manual lives on the bench, not in the drawer.

Cleaning, Inspection, Repair or Replacement: The Right Way

Section 5 is the only source I trust for wear limits. It lists the allowable end play for each shaft, the gear backlash spec, and the synchronizer clearance. You will find a table for bearing inner race to shaft interference fit. The cleaning instructions tell you to avoid caustic cleaners on the aluminum case because it will pit the bearing bores. That kind of note saves you from trashing a case. Replace synchronizer rings when the clearance exceeds 0.030 inch. Do not guess it — use the spec.

T5 HD Assembly: Getting the Order Right

Section 6 organizes the T5 HD assembly in sequential steps: install the cluster gear and bearings first, then the mainshaft with the synchronizer assembly, then the input shaft. Every shim selection is based on a measurement with a depth micrometer. The manual says to use the formula: (Bearing depth minus case depth) plus 0.002 inch for preload. If you do not measure, you will get a growl on deceleration. I have been down that road. The T5 STD assembly in Section 7 mirrors the same logic with the different mainshaft components. Pick the right section for the transmission tag on your case.

Why OEM Documentation Matters

Aftermarket manuals for the T5 are often photo-copied from an early edition or they merge the HD and STD procedures into one mess. This Spicer manual distinguishes the two from the start. The torque tables are drawn from Spicer engineering, not an internet forum. If you have worked on these transmissions before, you know the difference. If you are new, starting with the factory document keeps you from buying parts twice.

Related manuals you might need: Dana Spicer 1372-A Service Manual – Factory Specs & Rebuild Guide, Dana Spicer ES60-5, CM59, ES60-5A, ES60-5C, ES60-5D Service Manual, and Dana Spicer ES46-5 ES56-5 2002 Service Manual – 40 Pages of Factory Specs. For background on manual transmission design, see Manual Transmission and Manual Transmission on Wikipedia.

Will this manual help me rebuild a T5 from a Mustang?

Yes, if the transmission is a T5 WC or T5 STD. Many Mustang T5s are WC variants but check the tag code. The manual covers both but does not cover Borg-Warner T5 models with different tail housings. Get the tag number first.

Does it list fluid capacities?

It does. Section 2 lists 2.8 pints for the T5 STD and 3.0 pints for the T5 HD. Use Dexron III or equivalent ATF.

Are the torque specs for the case bolts included?

Yes, in Sections 6 and 7. Case bolt torque is 18-22 lb-ft for the T5 STD and 20-25 lb-ft for the T5 HD. Always use a torque wrench – the aluminum case strips easily.

What if my transmission has a different shift rail configuration?

The manual assumes the standard rail setup. If you have a remote shifter or a different tail housing (e.g., for a Jeep or GM), the shift cover removal steps may differ. You will need an additional supplement for those applications. This is strictly the base T5 WC and STD service procedures.

Do not go into your rebuild without the spec sheet on the bench. Access the Factory Manual and keep it open next to the parts washer. It will save you the cost of a replacement cluster gear.