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Disassembly And Assembly Of Subassemblies: MAINSHAFT: Assembly

WARNING: This page is about a different car, the 2009 Ford Pickup, 2009 Ford F550 Super Duty, 2009 Ford F450 Super Duty, and 2009 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Carry out the following:
    • Inspect and install new mainshaft gears if chipped, burred or badly worn.
    • Check the mainshaft gear end play. Install a new gear if the end play is not within specification.
    • Inspect and install a new mainshaft if it is out of round or worn, if the bearing surface is scored or the splines are worn or damaged.
    • Inspect and install a new speedometer drive gear if the gear teeth are worn or broken.
    2. CAUTION: Do not reassemble the mainshaft dry. Apply lubricant throughout the assembly procedure.
  2. Lubricate all mainshaft components with the recommended transmission lubricant during reassembly.
  3. Install the center mainshaft bearing.
    • Make sure the bearing is installed against the stop on the mainshaft.
    4. Fig 1: Center Mainshaft Bearing
    GF0007271Courtesy of FORD MOTOR CO.
  4. Using the special tool, position the mainshaft on the press with the input end facing upward.
    • Using a hammer and punch, remove the bearing cup from the intermediate housing, then install it on the bearing. This will prevent any damage to the bearing during installation.
    5. Fig 2: Special Tool & Mainshaft On Press
    GF0007272Courtesy of FORD MOTOR CO.
  5. Install the 1st gear bearing and first gear.
    6. Fig 3: Installing 1st Gear Bearing And 1st Gear
    GF0007273Courtesy of FORD MOTOR CO.
  6. Install the 3 synchronizer rings for 1st gear.
    • Make sure the tabs on the synchronizer ring are in the slots on the gear.
    • Make sure to align the notches on the synchronizer body with the tabs on the synchronizer ring.
    7. Fig 4: 1st Gear Synchronizer Rings (Aligned)
    GF0007274Courtesy of FORD MOTOR CO.
  7. Using the special tools, press the 1st and 2nd gear synchronizer body into place.
    • The numbers on the synchronizer hub must face upward.
    • Make sure to align the notches on the synchronizer body with the tabs on the synchronizer ring.
    8. Fig 5: Pressing 1st & 2nd Gear Synchronizer Body
    GF0007275Courtesy of FORD MOTOR CO.
    NOTE: Install the synchronizer sliding sleeve with the flats aligned with the detent notches.
  8. Install the synchronizer sliding sleeve.
    • The sliding sleeve has 3 flat areas which need to line up with the detent area of the synchronizer body.
    9. Fig 6: Synchronizer Sliding Sleeve
    GF0007276Courtesy of FORD MOTOR CO.
  9. Install the synchronizer spring and plate, then tilt the plate up and install the detent ball.
    • If the springs are difficult to install, check the alignment of the synchronizer sliding sleeve flat areas.
    10. Fig 7: Synchronizer Spring, Plate & Ball
    GF0007277Courtesy of FORD MOTOR CO.
    NOTE: Position the synchronizer into the neutral position.
  10. Install the synchronizer rings for 2nd gear.
    • Align the tabs on the synchronizer rings with the slots in the synchronizer body.
    11. Fig 8: 2nd Gear Synchronizer Rings (Aligned)
    GF0007278Courtesy of FORD MOTOR CO.
  11. Install the mainshaft 2nd gear bushing.
    12. Fig 9: Mainshaft 2nd Gear Bushing
    GF0007279Courtesy of FORD MOTOR CO.
    NOTE: Let the mainshaft 2nd gear bushing cool down for 2-4 minutes before trying to install the mainshaft needle bearing.
  12. Install the mainshaft needle bearing.
    13. Fig 10: Mainshaft Needle Bearing
    GF0007280Courtesy of FORD MOTOR CO.
  13. Install 2nd gear.
    • Make sure to align the tabs on the synchronizer ring with the slots on the gear.
    14. Fig 11: 2nd Gear
    GF0007281Courtesy of FORD MOTOR CO.
  14. Using the special tools, press the mainshaft 2nd gear thrust washer into place.
    15. Fig 12: Mainshaft 2nd Gear Thrust Washer
    GF0007282Courtesy of FORD MOTOR CO.
  15. Using the special tool, install the mainshaft 3rd gear bushing on the mainshaft.
    • Pull the 1st/2nd gear sliding sleeve into the neutral position.
    16. Fig 13: Mainshaft 3rd Gear Thrust Washer
    GF0007283Courtesy of FORD MOTOR CO.
    NOTE: Let the mainshaft 3rd gear bushing cool down for 2-4 minutes before trying to install the mainshaft needle bearing.
  16. Install the mainshaft needle bearing.
    17. Fig 14: Mainshaft Needle Bearing
    GF0007284Courtesy of FORD MOTOR CO.
  17. Install the mainshaft 3rd gear and synchronizer ring.
    18. Fig 15: Mainshaft 3rd Gear & Synchronizer Ring
    GF0007285Courtesy of FORD MOTOR CO.
  18. Install the 3rd and 4th gear synchronizer body.
    • The numbers on the synchronizer body must face upward.
    • Make sure to align the synchronizer body notches with the tabs on the synchronizer ring.
    19. Fig 16: 3rd & 4th Gear Synchronizer Body
    GF0007286Courtesy of FORD MOTOR CO.
  19. Install a new snap ring.
    • Install the snap ring with the small holes facing upward.
    • The snap ring is a selective fit. The correct snap ring should completely fill the groove when seated.
    20. Fig 17: Snap Ring
    GF0007287Courtesy of FORD MOTOR CO.
    CAUTION: Press the input shaft pocket bearing onto the mainshaft by the inner race only. Pressing on the outer race will damage the bearing.
  20. Press the input shaft pocket bearing into place.
    • Make sure the bearing is correctly seated. At the bottom of the bearing, there should be no gap. At the top of the bearing, check for a small amount of the mainshaft to be above the inner bearing race.
    21. Fig 18: Input Shaft Pocket Bearing
    GF0007288Courtesy of FORD MOTOR CO.
  21. Remove the mainshaft from the press and reinstall it in the Gear Pack Assembly Fixture.
  22. Install and position the synchronizer sliding sleeve down on the synchronizer body, install the springs and detents.
    23. Fig 19: Synchronizer Sliding Sleeve, Springs & Detents
    GF0007289Courtesy of FORD MOTOR CO.
  23. Install the synchronizer ring, then move the synchronizer sliding sleeve up on the synchronizer body.
    24. Fig 20: Synchronizer Ring
    GF0007290Courtesy of FORD MOTOR CO.
    CAUTION: Do not drive against the bearing cone. Drive against the inner race only.
  24. Using a suitable driver, install a new input shaft bearing.
    • Seat the bearing against its stop.
    25. Fig 21: Input Shaft Bearing
    GF0007291Courtesy of FORD MOTOR CO.
  25. Using the special tool, install the input shaft rear oil dam.
    • Rotate the input shaft to make sure the input shaft rear oil dam is completely seated.
    26. Fig 22: Installing Input Shaft Rear Oil Dam
    GF0007292Courtesy of FORD MOTOR CO.
  26. Install the input shaft.
    • Fill the input shaft pocket with a suitable engine assembly white grease.
    27. Fig 23: Mainshaft With Input Shaft Up
    GF0007258Courtesy of FORD MOTOR CO.
    NOTE: If the following axial gear clearances are not within specification, it will be necessary to disassemble and reinspect.
  27. Using the special tool, check the axial gear clearance at the mainshaft 1st gear.
    28. Fig 24: Checking Axial Gear Clearance At Mainshaft 1st Gear Using Special Tool (100-002, 308-021)
    GF0049375Courtesy of FORD MOTOR CO.
  28. Using the special tool, check the axial gear clearance at the mainshaft 2nd gear.
    29. Fig 25: Checking Axial Gear Clearance At Mainshaft 2nd Gear Using Special Tool (100-002, 308-021)
    GF0049376Courtesy of FORD MOTOR CO.
  29. Rotate the mainshaft with the input shaft facing downward. Using the special tool, check the axial gear clearance at the mainshaft 3rd gear.
    30. Fig 26: Checking Axial Gear Clearance At Mainshaft 3rd Gear Using Special Tool (100-002, 308-021)
    GF0049377Courtesy of FORD MOTOR CO.
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