Main Shaft: Disassembly

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.

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 the TRANSMISSION ASSEMBLY PROCEDURES .

Fig 1: Locating Input Shaft

Courtesy of FORD MOTOR CO.

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

Fig 2: Identifying Special Tools
Courtesy of FORD MOTOR CO.
Remove and discard the input shaft rear oil dam.

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

Fig 4: Locating Input Shaft
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: Identifying Special Tools
  Courtesy of FORD MOTOR CO.
Remove and discard the snap ring.

Fig 6: Locating Snap Ring
Courtesy of FORD MOTOR CO.
Using the special tools, remove the 3rd and 4th synchronizer assembly and 3rd gear.
- Inspect 3rd gear for wear or damage. Install a new gear as necessary.
  
  Fig 7: Identifying Special Tools
  Courtesy of FORD MOTOR CO.
Disassemble the 3rd and 4th synchronizer assembly.
- Inspect the components for wear or damage. Install new components as necessary.
  
  Fig 8: Exploded View Of 3rd And 4th 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: Identifying Gap Between 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: Locating 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: Identifying Special Tools

Courtesy of FORD MOTOR CO.

Using the special tool, press the mainshaft gear bushing off the mainshaft.
Using the special tool, press the mainshaft 2nd gear thrust washer, the mainshaft 2nd gear, the mainshaft needle bearing, the mainshaft gear bushing, 1st and 2nd synchronizer assembly and mainshaft 1st gear.
- Inspect the gears and bearing for wear or damage. Install new components as necessary.
  
  Fig 12: Identifying Special Tools
  Courtesy of FORD MOTOR CO.
Remove the mainshaft 1st gear needle bearing.
- Inspect the bearing for wear or damage. Install a new bearing as necessary.
  
  Fig 13: Identifying Mainshaft
  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: Identifying Special Tools
  Courtesy of FORD MOTOR CO.
Disassemble the 1st and 2nd synchronizer assembly.
- Inspect the components for wear or damage. Install a new synchronizer assembly as necessary.
  
  Fig 15: Exploded View Of 1st And 2nd 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: Identifying Gap Between 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.