Disassembly And Assembly Of Subassemblies: Mainshaft: Assembly

WARNING: This page is about a different car, the 2010 Ford F550 Super Duty and 2010 Ford F450 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.

Inspect the mainshaft and all mainshaft components for wear or damage. See Diagnosis and Testing, Manual Transmission and Clutch in MANUAL TRANSAXLE/TRANSMISSION AND CLUTCH - GENERAL INFORMATION .

NOTE: Do not reassemble the mainshaft dry. Apply lubricant throughout the assembly procedure or damage can occur on start-up.

NOTE: Lubricate all mainshaft components with the specified transmission fluid.

Fig 1: Locating Clutch Cone

Courtesy of FORD MOTOR CO.

Install the clutch cone.

NOTE: Install a new snap ring.

Fig 2: Locating Clutch Cone Snap Ring

Courtesy of FORD MOTOR CO.

Install the snap ring retaining the clutch cone.
Install the synchronizer ring.

Fig 3: Locating Synchronizer Ring
Courtesy of FORD MOTOR CO.
Install the reverse gear roller bearing.

Fig 4: Locating Reverse Gear Roller Bearing
Courtesy of FORD MOTOR CO.
Install the reverse gear and synchronizer assembly.

Fig 5: Locating Reverse Gear And Synchronizer Assembly
Courtesy of FORD MOTOR CO.

NOTE: The ball bearings are not interchangeable and must be aligned with the thrust washer notch.

Fig 6: Locating Thrust Washer And Ball Bearing

Courtesy of FORD MOTOR CO.

Install the ball bearing and the thrust washer.

NOTE: Drive the output shaft rear bearing onto the mainshaft by the inner race only. Using the outer race will damage the bearing. Press the bearing down until it is seated against the stop.

Fig 7: Installing Roller Bearing Onto Mainshaft

Courtesy of FORD MOTOR CO.

Using a suitable press, install the roller bearing onto the mainshaft.
Using a suitable press, install the 5th gear.

Fig 8: Installing 5th Gear
Courtesy of FORD MOTOR CO.
Invert the mainshaft assembly. Install the 1st gear roller bearing.

Fig 9: Locating 1st Gear Roller Bearing
Courtesy of FORD MOTOR CO.
Install the 1st gear.

Fig 10: Locating 1st Gear
Courtesy of FORD MOTOR CO.

NOTE: Align synchronizer assembly with the 3 grooves.

NOTE: Install a new snap ring.

Fig 11: Locating Snap Ring

Courtesy of FORD MOTOR CO.

Install the 1st and 2nd synchronizer assembly and the snap ring.

NOTE: Align the synchronizer assembly with the 3 grooves.

Fig 12: Locating 2nd Gear Synchronizer Ring

Courtesy of FORD MOTOR CO.

Install the 2nd gear synchronizer ring.

NOTE: Align the thrust washer notch with the ball bearing.

Fig 13: Locating Thrust Washer, Ball Bearing And Roller Bearings

Courtesy of FORD MOTOR CO.

Install the roller bearings, ball bearing and thrust washer.
Using a suitable press, install the 3rd gear bushing.

Fig 14: Installing 3rd Gear Bushing
Courtesy of FORD MOTOR CO.
Install the roller bearing.

Fig 15: Locating Roller Bearing
Courtesy of FORD MOTOR CO.
Install the 3rd gear.

Fig 16: Locating 3rd Gear
Courtesy of FORD MOTOR CO.
Install the 3rd synchronizer ring.

Fig 17: Locating 3rd Gear Synchronizer Ring
Courtesy of FORD MOTOR CO.
Install the 3rd and 4th gear synchronizer assembly.

Fig 18: Locating 3rd And 4th Gear Synchronizer Assembly
Courtesy of FORD MOTOR CO.
Install the 2 thrust washers and the roller bearing in between the thrust washers.

Fig 19: Locating Thrust Washers And Roller Bearing
Courtesy of FORD MOTOR CO.

NOTE: Installing a new input shaft will affect mainshaft clearance. Carry out mainshaft clearance measurement.

Fig 20: Locating Clutch Cone And Synchronizer Ring

Courtesy of FORD MOTOR CO.

Install the clutch cone and the synchronizer ring.