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Disassembly And Assembly Of Subassemblies: Mainshaft: Assembly

WARNING: This page is about a different variant/trim than selected.
    CAUTION: Be careful with the orientation of the reverse main gear.
    Fig 1: Positioning Reverse Main Gear On Mainshaft
    G03901808Courtesy of FORD MOTOR CO.
  1. Position the reverse main gear on the mainshaft.
  2. Using the special tool, install a new reverse main gear.
    Fig 2: Installing New Reverse Main Gear
    G03901809Courtesy of FORD MOTOR CO.
  3. Install the 1st main gear.
  4. Using the special tools, install the 1st main gear bushing.
    Fig 3: Installing 1st Main Gear Bushing
    G03901810Courtesy of FORD MOTOR CO.
  5. Install the 1st gear needle bearing.
  6. Install the 1st gear synchronizer ring.
    7. CAUTION: Make sure the synchronizer side with 3 notches is facing 1st gear and the synchronizer side with 4 notches is facing 2nd gear.
    Fig 4: Positioning New 1st And 2Nd Gear Synchronizer Assembly On Mainshaft
    G03901780Courtesy of FORD MOTOR CO.
  7. Position a new 1st and 2nd gear synchronizer assembly on the mainshaft.
  8. Using the special tools, install the 1st and 2nd gear synchronizer assembly.
    Fig 5: Installing 1st And 2nd Gear Synchronizer Assembly
    G03901812Courtesy of FORD MOTOR CO.
  9. Install the 2nd gear synchronizer ring.
  10. Using the special tools, install the 2nd gear bushing.
    Fig 6: Installing 2nd Gear Bushing
    G03901813Courtesy of FORD MOTOR CO.
  11. Install the 2nd gear needle bearing.
  12. Install the 2nd main gear.
    13. CAUTION: Be careful with the orientation of the 3rd main gear.
    Fig 7: Installing New 3rd Main Gear
    G03901814Courtesy of FORD MOTOR CO.
  13. Using the special tools, install a new 3rd main gear.
  14. Install the 3rd/4th main gear shaft spacer.
    15. CAUTION: Only one adjusting shim can be installed.
    Fig 8: Measuring Mainshaft Components Select 4th Main Gear Adjusting Shim
    G03901815Courtesy of FORD MOTOR CO.
  15. Measure the mainshaft components as indicated to select the appropriate 4th main gear adjusting shim. Refer to 4TH MAIN GEAR ADJUSTING SHIM SPECIFICATIONS  for shim thicknesses and install the 4th main gear adjusting shim:
    4TH MAIN GEAR ADJUSTING SHIM SPECIFICATIONS

    mm in
    0.52 0.021
    0.60 0.024
    0.68 0.027
    0.76 0.030
    0.84 0.033
    0.92 0.036
    1.00 0.039
    1.08 0.043
    16. CAUTION: Be careful with the orientation of the 4th main gear.
    Fig 9: Installing New 4th Main Gear
    G03901816Courtesy of FORD MOTOR CO.
  16. Using the special tool, install a new 4th main gear.
    17. CAUTION: Be careful with the orientation of the 5th main gear.
    Fig 10: Installing New 5th Main Gear
    G03901817Courtesy of FORD MOTOR CO.
  17. Using the special tool, install a new 5th main gear.
  18. Measure the gap between the snap ring and the 5th main gear. The end play should be less than 0.1 mm (0.0039 in). Refer to the following SNAP RING SPECIFICATIONS  to select the appropriate snap ring thickness and install a new snap ring:
    SNAP RING SPECIFICATIONS

    mm in
    1.85 0.073
    1.90 0.075
    1.95 0.077
    2.00 0.079
    2.05 0.081
    2.10 0.083
    2.15 0.085
    2.20 0.087
    Fig 11: Measuring Gap Between Snap Ring And 5th Main Gear
    G03901818Courtesy of FORD MOTOR CO.
    19. CAUTION: Be careful with the orientation of the mainshaft rear bearing.
    Fig 12: Installing Mainshaft Rear Bearing
    G03901819Courtesy of FORD MOTOR CO.
  19. Using the special tool, install the mainshaft rear bearing.
  20. Measure the gap between the mainshaft C-ring and the mainshaft rear bearing. Refer to the following C-RING THICKNESS SPECIFICATIONS  to select the appropriate C-ring thickness and install the C-ring:
    C-RING THICKNESS SPECIFICATIONS

    mm in
    2.535 0.0998
    2.565 0.1010
    2.595 0.1022
    2.625 0.1033
    2.655 0.1045
    2.685 0.1057
    2.715 0.1069
    2.745 0.1081
    2.775 0.1093
    2.805 0.1104
    2.835 0.1116
    2.865 0.1128
    2.895 0.1140
    2.925 0.1152
    2.955 0.1163
    2.985 0.1175
    3.015 0.1187
    3.045 0.1199
    3.075 0.1211
    Fig 13: Measuring Gap Between Mainshaft C-Ring And Mainshaft Rear Bearing
    G03901820Courtesy of FORD MOTOR CO.
  21. Install the C-ring holder.
  22. Install a new snap ring.
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