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Main Shaft: Assembly

WARNING: This page is about a different car, the 2006 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
  1. Inspect the mainshaft and all mainshaft components for wear or damage. For additional information, refer to MANUAL TRANSAXLE/TRANSMISSION AND CLUTCH - GENERAL INFORMATION .
    2. CAUTION: Do not reassembly the mainshaft dry. Apply lubricant throughout the assembly procedure.
  2. Lubricate all mainshaft components with the recommended transmission lubricant during reassembly.
  3. Install the center mainshaft bearing.
    • Make sure the bearing is installed against the stop on the mainshaft.
      Fig 1: Locating Center Mainshaft Bearing
      G04650521Courtesy of FORD MOTOR CO.
  4. Using the special tool, position the mainshaft on the press with the input end facing upward.
    • Using a hammer and punch, remove the bearing cup from the intermediate housing, then install it on the bearing. This will prevent any damage to the bearing during installation.
      Fig 2: Identifying Special Tools
      G04650522Courtesy of FORD MOTOR CO.
  5. Install the 1st gear bearing and first gear.
    Fig 3: Locating 1st Gear Bearing And First Gear
    G04650523Courtesy of FORD MOTOR CO.
  6. Install the 3 synchronizer rings for 1st gear.
    • Make sure the tabs on the synchronizer ring are in the slots on the gear.
    • Make sure to align the notches on the synchronizer body with the tabs on the synchronizer ring.
      Fig 4: Identifying Synchronizer Rings
      G04650524Courtesy of FORD MOTOR CO.
  7. Using the special tools, press the 1st and 2nd gear synchronizer body into place.
    • The numbers on the synchronizer hub must face downward.
    • Make sure to align the notches on the synchronizer body with the tabs on the synchronizer ring.
      Fig 5: Locating Synchronizer Hub
      G04650525Courtesy of FORD MOTOR CO.
    8. NOTE: Install the synchronizer sliding sleeve with the flats aligned with the detent notches.
  8. Install the synchronizer sliding sleeve.
    • The sliding sleeve has 3 fiat areas which need to line up with the detent area of the synchronizer body.
      Fig 6: Locating Synchronizer Sliding Sleeve
      G04650526Courtesy of FORD MOTOR CO.
  9. Install the synchronizer spring and plate, then tilt the plate up and install the detent ball.
    • If the springs are difficult to install, check the alignment of the synchronizer sliding sleeve flat areas.
      Fig 7: Locating Synchronizer Spring And Plate
      G04650527Courtesy of FORD MOTOR CO.
    10. NOTE: Position the synchronizer into the neutral position.
  10. Install the synchronizer rings for 2nd gear.
    • Align the tabs on the synchronizer rings with the slots in the synchronizer body.
      Fig 8: Locating Synchronizer Rings
      G04650528Courtesy of FORD MOTOR CO.
  11. Install the mainshaft 2nd gear bushing.
    Fig 9: Locating Mainshaft 2nd Gear Bushing
    G04650529Courtesy of FORD MOTOR CO.
    12. NOTE: Let the mainshaft 2nd gear bushing cool down for 2-4 minutes before trying to install the mainshaft needle bearing.
    Fig 10: Locating Mainshaft Needle Bearing
    G04650530Courtesy of FORD MOTOR CO.
  12. Install the mainshaft needle bearing.
  13. Install 2nd gear.
    • Make sure to align the tabs on the synchronizer ring with the slots on the gear.
      Fig 11: Locating 2nd Gear
      G04650531Courtesy of FORD MOTOR CO.
  14. Using the special tools, press the mainshaft 2nd gear thrust washer into place.
    Fig 12: Identifying Special Tools
    G04650532Courtesy of FORD MOTOR CO.
  15. Using the special tool, install the mainshaft 3rd gear bushing on the mainshaft.
    • Pull the 1st/2nd gear sliding sleeve into the NEUTRAL position.
      Fig 13: Locating Mainshaft 3rd Gear Bushing
      G04650533Courtesy of FORD MOTOR CO.
    16. NOTE: Let the mainshaft 3rd gear bushing cool down for 2-4 minutes before trying to install the mainshaft needle bearing.
    Fig 14: Locating Mainshaft Needle Bearing
    G04650534Courtesy of FORD MOTOR CO.
  16. Install the mainshaft needle bearing.
  17. Install the mainshaft 3rd gear and synchronizer ring.
    Fig 15: Locating Mainshaft 3rd Gear And Synchronizer Ring
    G04650535Courtesy of FORD MOTOR CO.
  18. Install the 3rd and 4th gear synchronizer body.
    • The numbers on the synchronizer body must face upward.
    • Make sure to align the synchronizer body notches with the tabs on the synchronizer ring.
      Fig 16: Locating Synchronizer Ring
      G04650536Courtesy of FORD MOTOR CO.
  19. Install a new snap ring.
    • Install the snap ring with the small holes facing upward.
    • The snap ring is a selective fit. The correct snap ring should completely fill the groove when seated.
      Fig 17: Locating Snap Ring
      G04650537Courtesy of FORD MOTOR CO.
    20. CAUTION: Press the input shaft pocket bearing onto the mainshaft by the inner race only. Pressing on the outer race will damage the bearing.
  20. Press the input shaft pocket bearing into place.
    • Make sure the bearing is correctly seated. At the bottom of the bearing, there should be no gap. At the top of the bearing, check for a small amount of the mainshaft to be above the inner bearing race.
      Fig 18: Locating Input Shaft Pocket Bearing
      G04650538Courtesy of FORD MOTOR CO.
  21. Remove the mainshaft from the press and reinstall it in the Gear Pack Assembly Fixture.
  22. Install and position the synchronizer sliding sleeve down on the synchronizer body, install the springs and detents.
    Fig 19: Locating Synchronizer Sliding Sleeve
    G04650539Courtesy of FORD MOTOR CO.
  23. Install the synchronizer ring, then move the synchronizer sliding sleeve up on the synchronizer body.
    Fig 20: Locating Synchronizer Ring
    G04650540Courtesy of FORD MOTOR CO.
    24. CAUTION: Do not drive against the bearing cone. Drive against the inner race only.
  24. Using a suitable driver, install a new input shaft bearing.
    • Seat the bearing against its stop.
      Fig 21: Locating Input Shaft Bearing
      G04650541Courtesy of FORD MOTOR CO.
  25. Using the special tool, install the input shaft rear oil dam.
    • Rotate the input shaft to make sure the input shaft rear oil dam is completely seated.
      Fig 22: Identifying Special Tool
      G04650542Courtesy of FORD MOTOR CO.
  26. Install the input shaft.
    • Fill the input shaft pocket with a suitable engine assembly white grease.
      Fig 23: Locating Input Shaft
      G04650543Courtesy of FORD MOTOR CO.
    27. NOTE: If the following axial gear clearances are not within specification, it will be necessary to disassemble and reinspect.
    Fig 24: Checking Axial Gear Clearance
    G04650544Courtesy of FORD MOTOR CO.
  27. Using the special tool, check the axial gear clearance at the mainshaft 1st gear.
  28. Using the special tool, check the axial gear clearance at the mainshaft 2nd gear.
    Fig 25: Checking Axial Gear Clearance
    G04650545Courtesy of FORD MOTOR CO.
  29. Rotate the mainshaft with the input shaft facing downward. Using the special tool, check the axial gear clearance at the mainshaft 3rd gear.
    Fig 26: Checking Axial Gear Clearance
    G04650546Courtesy of FORD MOTOR CO.
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