Main Shaft: Disassembly

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.

Rotate the mainshaft. Position the mainshaft in the Gear Pack Assembly Fixture with the input shaft pointing upward.

NOTE: Installing a new input shaft will affect mainshaft clearance. Carry out a mainshaft clearance measurement. Refer to transmissionASSEMBLY procedures.

Fig 1: Removing Input Shaft

Courtesy of FORD MOTOR CO.

Remove the input shaft.
Using the special tools, remove and discard the input shaft bearing.

Fig 2: Removing Input Shaft Bearing
Courtesy of FORD MOTOR CO.
Remove and discard the input shaft rear oil dam.

Fig 3: Removing Input Shaft Rear Oil Dam
Courtesy of FORD MOTOR CO.
Inspect the input shaft and input shaft bearing for damage or wear. Refer to MANUAL TRANSAXLE/TRANSMISSION AND CLUTCH - GENERAL INFORMATION .

Fig 4: Inspecting Input Shaft And Input Shaft Bearing
Courtesy of FORD MOTOR CO.

CAUTION: To prevent damage, do not heat the bearing higher than 150°C (300°F).

A new input shaft bearing should be heated in advance of the assembly procedure. Heating components will ease the assembly process. Place the input shaft bearing into the Gear/Bearing Heater. Make sure the bearing is heated to 150°C (300°F).
Using the special tools, remove the input shaft pocket bearing.
- Inspect the bearing for wear or damage. Install a new bearing as necessary.
  
  Fig 5: Removing Input Shaft Pocket Bearing
  Courtesy of FORD MOTOR CO.
Remove and discard the snap ring.

Fig 6: Removing Snap Ring
Courtesy of FORD MOTOR CO.
Using the special tools, remove the third and fourth synchronizer assembly and third gear.
- Inspect third gear for wear or damage. Install a new gear as necessary.
  
  Fig 7: Removing Third And Fourth Synchronizer Assembly And Third Gear
  Courtesy of FORD MOTOR CO.
Disassemble the third and fourth synchronizer assembly.
- Inspect the components for wear or damage. Install new components as necessary.
  
  Fig 8: Disassembling Third And Fourth Synchronizer Assembly
  Courtesy of FORD MOTOR CO.
Check the clearance between the synchronizer ring and the gear.
1. Place the synchronizer ring onto the synchronizer sliding sleeve. Position the synchronizer ring on the gear.
2. Insert a feeler gauge and measure the clearance, while applying pressure and rotating the synchronizer ring. The clearance should be the same around the entire circumference.
  - Place the feeler gauge between the ring and gear clutching teeth. The ring has a raised section, inserting the feeler gauge past the teeth will give an incorrect reading.
  - If the clearance is less than 1.0 mm (0.04 in), install a new synchronizer assembly.
    
    Fig 9: Checking Clearance Between Synchronizer Ring And Gear
    Courtesy of FORD MOTOR CO.
Remove the mainshaft needle bearing.
- Inspect the bearing for wear or damage. Install a new bearing as necessary.
  
  Fig 10: Removing Mainshaft Needle Bearing
  Courtesy of FORD MOTOR CO.

NOTE: When installing the Bearing Puller, make sure it is installed above the mainshaft bearing race.

Fig 11: Pressing Mainshaft Gear Bushing Off Mainshaft

Courtesy of FORD MOTOR CO.

Using the special tool, press the mainshaft gear bushing off the mainshaft.
Using the special tool, press the mainshaft second gear thrust washer, the mainshaft second gear, the mainshaft needle bearing, the mainshaft gear bushing, first and second synchronizer assembly and mainshaft first gear.
- Inspect the gears and bearing for wear or damage. Install new components as necessary.
  
  Fig 12: Pressing Mainshaft Second Gear Thrust Washer
  Courtesy of FORD MOTOR CO.
Remove the mainshaft first gear needle bearing.
- Inspect the bearing for wear or damage. Install a new bearing as necessary.
  
  Fig 13: Removing Mainshaft First Gear Needle Bearing
  Courtesy of FORD MOTOR CO.
Using the special tools, remove the mainshaft center bearing.
- Inspect the bearing for wear or damage. Install a new bearing as necessary.
  
  Fig 14: Removing Mainshaft Center Bearing
  Courtesy of FORD MOTOR CO.
Disassemble the first and second synchronizer assembly.
- Inspect the components for wear or damage. Install a new synchronizer assembly as necessary.
  
  Fig 15: Disassembling First And Second Synchronizer Assembly
  Courtesy of FORD MOTOR CO.
Check the clearance between the synchronizer ring and the gear clutching teeth.
1. Place the synchronizer ring onto the synchronizer sliding sleeve. Position the synchronizer ring on the gear.
2. Insert a feeler gauge and measure the clearance, while applying pressure and rotating the synchronizer ring. The clearance should be the same around the entire circumference.
  - Place the feeler gauge between the ring and gear clutching teeth. The ring has a raised section, inserting the feeler gauge past the teeth will give a wrong reading.
  - If the clearance is less than 1.0 mm (0.04 in), install a new synchronizer assembly.
    
    Fig 16: Checking Clearance Between Synchronizer Ring And Gear Clutching Teeth
    Courtesy of FORD MOTOR CO.

CAUTION: To prevent damage, do not heat bearings, thrust washers, bushings or the synchronizer bodies higher than 150°C (300°F).

New or original components should be heated in advance of the assembly procedure. Heating the specified components will ease the assembly process. Place the input shaft pocket bearing, the mainshaft second gear thrust washer, the mainshaft center bearing, the synchronizer bodies and the mainshaft gear bushings into the Gear/Bearing Heater.