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Disassembly And Assembly Of Subassemblies: Mainshaft: Assembly

WARNING: This page is about a different car, the 2010 Ford Pickup, 2010 Ford F550 Super Duty, 2010 Ford F450 Super Duty, and 2010 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. NOTE: Do not reassemble the mainshaft dry. Apply lubricant throughout the assembly procedure or damage to the components can occur.
  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.
      Fig 1: Locating Center Mainshaft Bearing
      G06778874Courtesy of FORD MOTOR CO.
  4. Using the 17.5 Ton Press and the Bearing Puller, 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.
      Fig 2: Pressing Bearing
      G06778875Courtesy of FORD MOTOR CO.
  5. Install the 1st gear bearing and 1st gear.
    Fig 3: Installing First Gear Bearing And First Gear
    G06778876Courtesy 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.
      Fig 4: Installing Three Synchronizer Rings For First Gear
      G06778877Courtesy of FORD MOTOR CO.
  7. Using the Thrust Washer Bearing Cup Remover/Installer, 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.
      Fig 5: Pressing 1St And 2Nd Gear Synchronizer Body
      G06778878Courtesy of FORD MOTOR CO.
    8. 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.
      Fig 6: Installing Synchronizer Sliding Sleeve
      G06778879Courtesy 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.
      Fig 7: Installing Synchronizer Spring, Plate And Detent Ball
      G06778880Courtesy of FORD MOTOR CO.
    10. 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.
      Fig 8: Installing Synchronizer Rings For Second Gear
      G06778881Courtesy of FORD MOTOR CO.
  11. Install the mainshaft 2nd gear bushing.
    Fig 9: Installing Mainshaft Second Gear Bushing
    G06778882Courtesy of FORD MOTOR CO.
    12. NOTE: Let the mainshaft 2nd gear bushing cool down for 2-4 minutes before trying to install the mainshaft needle bearing.
    Fig 10: Installing Mainshaft Needle Bearing
    G06778883Courtesy of FORD MOTOR CO.
  12. Install the mainshaft needle bearing.
  13. Install the 2nd gear.
    • Make sure to align the tabs on the synchronizer ring with the slots on the gear.
      Fig 11: Installing Second Gear
      G06778884Courtesy of FORD MOTOR CO.
  14. Using the Thrust Washer Guide and the Thrust Washer Bearing Cup Remover/Installer, press the mainshaft 2nd gear thrust washer into place.
    Fig 12: Pressing Mainshaft 2Nd Gear Thrust Washer
    G06778885Courtesy of FORD MOTOR CO.
  15. Using a suitable tool, install the mainshaft 3rd gear bushing on the mainshaft.
    • Pull the 1st/2nd gear sliding sleeve into the neutral position.
      Fig 13: Installing Mainshaft Third Gear Bushing On Mainshaft
      G06778886Courtesy of FORD MOTOR CO.
    16. NOTE: Let the mainshaft 3rd gear bushing cool down for 2-4 minutes before trying to install the mainshaft needle bearing.
    Fig 14: Installing Mainshaft Needle Bearing
    G06778887Courtesy of FORD MOTOR CO.
  16. Install the mainshaft needle bearing.
  17. Install the mainshaft 3rd gear and synchronizer ring.
    Fig 15: Installing Mainshaft Third Gear And Synchronizer Ring
    G06778888Courtesy 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.
      Fig 16: Installing Third And Fourth Gear Synchronizer Body
      G06778889Courtesy 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.
      Fig 17: Installing Snap Ring
      G06778890Courtesy of FORD MOTOR CO.
    20. NOTE: 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.
      Fig 18: Pressing Input Shaft Pocket Bearing Onto Mainshaft
      G06778891Courtesy of FORD MOTOR CO.
  21. Remove the mainshaft from the press and reinstall it in the Gear Pack Fixture.
  22. Install and position the synchronizer sliding sleeve down on the synchronizer body, install the springs and detents.
    Fig 19: Installing Synchronizer Sliding Sleeve Down On Synchronizer Body
    G06778892Courtesy of FORD MOTOR CO.
  23. Install the synchronizer ring, then move the synchronizer sliding sleeve up on the synchronizer body.
    Fig 20: Locating Synchronizer Ring
    G06778893Courtesy of FORD MOTOR CO.
    24. NOTE: Do not drive against the bearing cone. Drive against the inner race only or damage to the components can occur.
  24. Using a suitable driver, install a new input shaft bearing.
    • Seat the bearing against its stop.
      Fig 21: Installing Input Shaft Bearing
      G06778894Courtesy of FORD MOTOR CO.
  25. Using the Wheel Speed Sensor Ring Installer, install the input shaft rear oil dam.
    • Rotate the input shaft to make sure the input shaft rear oil dam is completely seated.
      Fig 22: Installing Input Shaft Rear Oil Dam
      G06778895Courtesy of FORD MOTOR CO.
  26. Install the input shaft.
    • Fill the input shaft pocket with a suitable engine assembly white grease.
      Fig 23: Identifying Input Shaft
      G06778858Courtesy of FORD MOTOR CO.
    27. NOTE: If the following axial gear clearances are not within specification, it will be necessary to disassemble and reinspect.
    Fig 24: Checking Axial Gear Clearance At Mainshaft 1St Gear
    G06778897Courtesy of FORD MOTOR CO.
  27. Using the Dial Indicator Gauge with Holding Fixture and the Clutch Housing Gauge, check the axial gear clearance at the mainshaft 1st gear.
  28. Using the Dial Indicator Gauge with Holding Fixture and the Clutch Housing Gauge, check the axial gear clearance at the mainshaft 2nd gear.
    Fig 25: Checking Axial Gear Clearance At Mainshaft 2Nd Gear
    G06778898Courtesy of FORD MOTOR CO.
  29. Rotate the mainshaft with the input shaft facing downward. Using the Dial Indicator Gauge with Holding Fixture and the Clutch Housing Gauge, check the axial gear clearance at the mainshaft 3rd gear.
    Fig 26: Checking Axial Gear Clearance At Mainshaft 3Rd Gear
    G06778899Courtesy of FORD MOTOR CO.
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