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How To Rebuild A Top Loader Four-Speed

Ford Top Loader Transmission Gears
Here, we have four gears.... 
   
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Ford Top Loader Transmission Gears
Here, we have four gears. On top is Second gear in 28-tooth (left) and 31-tooth (right), the latter being wide-ratio. On the bottom is a pair of Third gears, both 25-tooth, which applies to close- and wide-ratio.
Wide-ratio is the most common Top Loader. Gear ratios stack up like this:
First Gear:2.78:1
Second Gear:1.93:1
Third Gear:1.36:1
Fourth Gear:1.00:1 (Straight Drive)
Close-ratio stacks up like this:
First Gear:2.32:1
Second Gear:1.69:1
Third Gear:1.29:1
Fourth Gear:1.00:1 (Straight Drive)

Wide-Ratio looks like this: GearCluster Gear
First Gear:32 Teeth15
Second Gear:31 Teeth21
Third Gear:25 Teeth24
Fourth Gear:23 Teeth30
Close Ratio looks like this:
First Gear:32 Teeth15
Second Gear:28 Teeth18
Third Gear:25 Teeth21
Fourth Gear:23 Teeth25

Ford Top Loader Transmission Assembly Guide
Assembly begins with shifter... 
   
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Ford Top Loader Transmission Assembly Guide
Assembly begins with shifter cams, which go in the case as shown. Each needs a lubricated rubber O-ring to keep the gear lube inside.
Ford Top Loader Transmission Shifter Cams
Observe cam positioning in... 
   
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Ford Top Loader Transmission Shifter Cams
Observe cam positioning in the case. Note proper location of shifter levers. This is something you don't want to get backward.
Ford Top Loader Transmission Needle Bearings
New needle bearings are loaded... 
   
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Ford Top Loader Transmission Needle Bearings
New needle bearings are loaded into the reverse idler, which is what goes in first. There are 22 needle bearings (Ford PN 7D271) in each end. Use transmission assembly lube and embed the bearings to create a perfect circle.
Ford Top Loader Transmission Reverse Idler
Here's the reverse idler and... 
   
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Ford Top Loader Transmission Reverse Idler
Here's the reverse idler and gear installed. Refer to the Ford shop manual for proper order of idler gear, retainer, and thrust washers.
Ford Top Loader Transmission Reverse Idler Shifter Fork
The Reverse idler shifter... 
   
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Ford Top Loader Transmission Reverse Idler Shifter Fork
The Reverse idler shifter fork and rail go in like this. Use plenty of assembly lube.
Ford Top Loader Transmission Needle Bearings
The cluster gear gets 21 needle... 
   
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Ford Top Loader Transmission Needle Bearings
The cluster gear gets 21 needle bearings in each end. Again, use assembly lube to retain the needles. Always use all-new needle bearings.
Ford Top Loader Transmission Cluster Gear Thrust Washer
Cluster gear thrust washers... 
   
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Ford Top Loader Transmission Cluster Gear Thrust Washer
Cluster gear thrust washers go in the case at each end like this.
Ford Top Loader Transmission Installed Transmission
This is what the cluster gear/countershaft... 
   
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Ford Top Loader Transmission Installed Transmission
This is what the cluster gear/countershaft and reverse idler should look like installed. We've gone to a close-ratio package with a 25/21/18/15-tooth package.
Ford Top Loader Transmission Gear Teeth
For smoother shifts, Anaheim... 
   
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Ford Top Loader Transmission Gear Teeth
For smoother shifts, Anaheim Gear massages the gear teeth. When you compare the Ford Top Loader to Borg-Warner's T-10, one of the major differences is smoother shifts from the T-10.
Ford Top Loader Transmission Output Shaft
One of the first important... 
   
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Ford Top Loader Transmission Output Shaft
One of the first important ingredients is the 31-spline output shaft for our close-ratio Top Loader. A 28-spline output shaft is fine for most street applications. But since we'll be running 600 hp through this box, we're using the 31-spline shaft.
Ford Top Loader Transmission Manual Illustration
Assembly is straightforward... 
   
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Ford Top Loader Transmission Manual Illustration
Assembly is straightforward by following this Ford shop manual illustration. The output shaft serves as a foundation for synchronizers, gears, and blocking rings. What you want is smooth operation with proper prep and close inspection before it all goes together.
Ford Top Loader Transmission Gears
Anaheim Gear dresses up all... 
   
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Ford Top Loader Transmission Gears
Anaheim Gear dresses up all the hard parts and their mating surfaces for smooth operation. The goal is to remove any irregularities and high spots. This also enhances lubrication control as well, keeping lube where it belongs between moving parts.

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