Disassembly And Assembly Of Subassemblies: Mainshaft: Disassembly

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.

NOTE: Use the yoke to support the mainshaft in the upright position.

Fig 1: Locating Clutch Cone And Synchronizer Ring

Courtesy of FORD MOTOR CO.

Remove the clutch cone and the synchronizer ring.
Remove the 2 thrust washers and the roller bearing between the thrust washers.

Fig 2: Locating Thrust Washers And Roller Bearing
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Remove the 3rd and 4th gear synchronizer assembly.

Fig 3: Locating 3rd And 4th Gear Synchronizer Assembly
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Remove the 3rd gear synchronizer ring.

Fig 4: Locating 3rd Gear Synchronizer Ring
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Remove the 3rd gear.

Fig 5: Locating 3rd Gear
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Remove the roller bearing.

Fig 6: Locating Roller Bearing
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Using the 2 or 3 Jaw Puller, remove the 3rd gear bushing and the 2nd gear.

Fig 7: Removing 3rd Gear Bushing And 2nd Gear
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NOTE: A ball bearing is between the thrust washer and the mainshaft. The ball bearings are not interchangeable.

Fig 8: Locating Thrust Washer, Ball Bearing And Roller Bearings

Courtesy of FORD MOTOR CO.

Remove the thrust washer, ball bearing and roller bearings.
Remove the 2nd gear synchronizer ring.

Fig 9: Locating 2nd Gear Synchronizer Ring
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Remove the snap ring retaining the 1st and 2nd synchronizer assembly.
- Discard the snap ring.
  
  Fig 10: Locating Snap Ring
  Courtesy of FORD MOTOR CO.
Using the Bearing Puller and a suitable press, remove the 1st and 2nd gear synchronizer assembly and the 1st gear.

Fig 11: Removing 1st And 2nd Gear Synchronizer Assembly And 1st Gear
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Remove the 1st gear roller bearing.

Fig 12: Locating 1st Gear Roller Bearing
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Invert the mainshaft. Using the Bearing Puller and a suitable press, remove the 5th gear and roller bearing.

Fig 13: Removing 5th Gear And Roller Bearing
Courtesy of FORD MOTOR CO.

NOTE: A ball bearing is between the thrust washer and the mainshaft. The ball bearings are not interchangeable.

Fig 14: Locating Thrust Washer And Ball Bearing

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Remove the thrust washer and the ball bearing.
Remove the reverse gear and synchronizer assembly.

Fig 15: Locating Reverse Gear And Synchronizer Assembly
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Remove the reverse gear roller bearing.

Fig 16: Locating Reverse Gear Roller Bearing
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Remove the synchronizer ring.

Fig 17: Locating Synchronizer Ring
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Remove the snap ring retaining the clutch cone.
- Discard the snap ring.
  
  Fig 18: Locating Clutch Cone Snap Ring
  Courtesy of FORD MOTOR CO.
Remove the clutch cone.

Fig 19: Locating Clutch Cone
Courtesy of FORD MOTOR CO.