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Main Shaft: Assembly

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, and 2004 Ford Cab & Chassis. 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. 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: Installing Center Mainshaft Bearing
      G02776499Courtesy 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: Removing Bearing Cup From Intermediate Housing
      G02776500Courtesy of FORD MOTOR CO.
  5. Install the first gear bearing and first gear.
    Fig 3: Installing First Gear Bearing And First Gear
    G02776501Courtesy of FORD MOTOR CO.
  6. Install the three synchronizer rings for first 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: Installing Three Synchronizer Rings For First Gear
      G02776502Courtesy of FORD MOTOR CO.
  7. Using the special tools, press the first and second 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: Pressing First And Second Gear Synchronizer Body Into Place
      G02776503Courtesy 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 three flat areas which need to line up with the detent area of the synchronizer body.
      Fig 6: Installing Synchronizer Sliding Sleeve
      G02776504Courtesy 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: Installing Synchronizer Spring And Plate
      G02776505Courtesy of FORD MOTOR CO.
    10. NOTE: Position the synchronizer into the neutral position.
  10. Install the synchronizer rings for second gear.
    • Align the tabs on the synchronizer rings with the slots in the synchronizer body.
      Fig 8: Aligning Tabs On Synchronizer Rings With Slots In Synchronizer Body
      G02776506Courtesy of FORD MOTOR CO.
  11. Install the mainshaft second gear bushing.
    Fig 9: Installing Mainshaft Second Gear Bushing
    G02776507Courtesy of FORD MOTOR CO.
    12. NOTE: Let the mainshaft second gear bushing cool down for 2-4 minutes before trying to install the mainshaft needle bearing.
    Fig 10: Identifying Mainshaft Needle Bearing
    G02776508Courtesy of FORD MOTOR CO.
  12. Install the mainshaft needle bearing.
  13. Install second gear.
    • Make sure to align the tabs on the synchronizer ring with the slots on the gear.
      Fig 11: Installing Second Gear
      G02776509Courtesy of FORD MOTOR CO.
  14. Using the special tools, press the mainshaft second gear thrust washer into place.
    Fig 12: Pressing Mainshaft Second Gear Thrust Washer Into Place
    G02776510Courtesy of FORD MOTOR CO.
  15. Using the special tool, install the mainshaft third gear bushing on the mainshaft.
    • Pull the first/second gear sliding sleeve into the neutral position.
      Fig 13: Installing Mainshaft Third Gear Bushing On Mainshaft
      G02776511Courtesy of FORD MOTOR CO.
    16. NOTE: Let the mainshaft third gear bushing cool down for 2-4 minutes before trying to install the mainshaft needle bearing.
    Fig 14: Installing Mainshaft Needle Bearing
    G02776512Courtesy of FORD MOTOR CO.
  16. Install the mainshaft needle bearing.
  17. Install the mainshaft third gear and synchronizer ring.
    Fig 15: Installing Mainshaft Third Gear And Synchronizer Ring
    G02776513Courtesy of FORD MOTOR CO.
  18. Install the third and fourth 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: Installing Third And Fourth Gear Synchronizer Body
      G02776514Courtesy 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: Installing Snap Ring
      G02776515Courtesy 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: Pressing Input Shaft Pocket Bearing Into Place
      G02776516Courtesy 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: Installing Springs And Detents
    G02776517Courtesy of FORD MOTOR CO.
  23. Install the synchronizer ring, then move the synchronizer sliding sleeve up on the synchronizer body.
    Fig 20: Installing Synchronizer Ring
    G02776518Courtesy 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: Installing Input Shaft Bearing
      G02776519Courtesy 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: Installing Input Shaft Rear Oil Dam
      G02776520Courtesy of FORD MOTOR CO.
  26. Install the input shaft.
    • Fill the input shaft pocket with a suitable engine assembly white grease.
      Fig 23: Installing Input Shaft
      G02776521Courtesy 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 At Mainshaft First Gear
    G02776522Courtesy of FORD MOTOR CO.
  27. Using the special tool, check the axial gear clearance at the mainshaft first gear.
  28. Using the special tool, check the axial gear clearance at the mainshaft second gear.
    Fig 25: Checking Axial Gear Clearance At Mainshaft Second Gear
    G02776523Courtesy 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 third gear.
    Fig 26: Checking Axial Gear Clearance At Mainshaft Third Gear
    G02776524Courtesy of FORD MOTOR CO.
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