5th/6th Gear

WARNING: This page is about a different car, the 2012 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

Inspect the 5th and 6th gear synchronizer cones, gear teeth and rings for wear or damage. Replace as necessary.

NOTE: Set the synchronizer ring squarely on the gear and measure around the circumference.

Fig 1: Measuring Clearance Between 5th Gear Synchronizer Ring And Flank Surface Of Gear Using Feeler Gauge

Courtesy of FORD MOTOR CO.

Using a feeler gauge, while applying pressure and rotating the synchronizer ring, measure the clearance between the 5th gear synchronizer ring and the flank surface of the gear. The measurement should be the same around the entire circumference. Replace the synchronizer ring if less than the minimum specification.

5TH GEAR SYNCHRONIZER RING CLEARANCE

Standard	Minimum
1.50 mm (0.059 in)	0.80 mm (0.031 in)

NOTE: Set the synchronizer ring squarely on the gear and measure around the circumference.

Fig 2: Measuring Clearance Between 6th Gear Synchronizer Ring And Flank Surface Of Gear Using Feeler Gauge

Courtesy of FORD MOTOR CO.

Using a feeler gauge, while applying pressure and rotating the synchronizer ring, measure the clearance between the 6th gear synchronizer ring and the flank surface of the gear. The measurement should be the same around the entire circumference. Replace the synchronizer ring if less than the minimum specification.

6TH GEAR SYNCHRONIZER RING CLEARANCE

Standard	Minimum
1.50 mm (0.059 in)	0.80 mm (0.031 in)

Measure the clearance between the clutch hub sleeve and the shift fork. Replace if it exceeds the maximum specification.

Inspect the clutch hub sleeve and clutch hub operation. Replace if there is a malfunction.

5TH/6TH GEAR CLUTCH HUB SLEEVE AND SHIFT FORK CLEARANCE

Standard	Maximum
0.10-0.36 mm (0.004-0.014 in)	0.86 mm (0.033 in)

Fig 3: Measuring Clearance Between Clutch Hub Sleeve And Shift Fork Using Feeler Gauge

Courtesy of FORD MOTOR CO.

Using a telescoping gauge, measure the ID of the 5th gear. Using a micrometer, measure the OD of the gear sleeve.

Fig 4: Measuring OD Of Gear Sleeve Using Micrometer And ID Of 5th Gear Using Telescoping Gauge
Courtesy of FORD MOTOR CO.
Measure the telescoping gauge to determine if the gear to the gear sleeve clearances are within specifications. If not within specifications, replace as needed.

Fig 5: Measuring Telescoping Gauge Reading Using Micrometer
Courtesy of FORD MOTOR CO.
Using a telescoping gauge, measure the ID of the 6th gear. Using a micrometer, measure the OD of the gear sleeve.

Fig 6: Measuring OD Of Gear Sleeve Using Micrometer And ID Of 6th Gear Using Telescoping Gauge
Courtesy of FORD MOTOR CO.

Measure the telescoping gauge to determine if the gear to the gear sleeve clearances are within specifications. If not within specifications, replace as needed.

5TH AND 6TH GEAR OIL CLEARANCE

Gear	Gear ID	Gear Sleeve OD	Clearance
5th	34.00- 34.025 mm (1.3386- 1.3395 in)	33.945- 33.970 mm (1.3365- 1.3373 in)	0.030- 0.80 mm (0.001- 0.003 in)
6th	34.00- 34.025 mm (1.3386- 1.3395 in)	33.945- 33.970 mm (1.3365- 1.3373 in)	0.030- 0.80 mm (0.001- 0.003 in)

Fig 7: Measuring Telescoping Gauge Reading Using Micrometer

Courtesy of FORD MOTOR CO.