Disassembly And Assembly Of Subassemblies: Mainshaft: Disassembly

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.

Rotate the mainshaft. Position the mainshaft in the Gear Pack Fixture with the input shaft pointing upward.

NOTE: Installing a new input shaft will affect mainshaft clearance. Carry out a mainshaft clearance measurement. For additional information, refer to the TRANSMISSION ASSEMBLY PROCEDURES .

Fig 1: Locating Input Shaft

Courtesy of FORD MOTOR CO.

Remove the input shaft.
Using the Shaft Protector Set, 2 or 3 Jaw Puller and the Bearing Puller, remove and discard the input shaft bearing.

Fig 2: Removing Input Shaft Bearing
Courtesy of FORD MOTOR CO.
Remove and discard the input shaft rear oil dam.

Fig 3: Removing Input Shaft Rear Oil Dam
Courtesy of FORD MOTOR CO.
Inspect the input shaft and input shaft bearing for damage or wear. For additional information, refer to MANUAL TRANSAXLE/TRANSMISSION AND CLUTCH - GENERAL INFORMATION .
- Inspect the input shaft splines for wear and damage. Install a new shaft as necessary.
  
  Fig 4: Locating Input Shaft And Input Shaft Bearing For Damage Or Wear
  Courtesy of FORD MOTOR CO.

NOTE: To prevent damage, do not heat the bearing higher than 150°C (302°F).

A new input shaft bearing should be heated in advance of the assembly procedure. Heating components will ease the assembly process. Place the input shaft bearing into the Gear/Bearing Heater. Make sure the bearing is heated to 150°C (302°F).
Using the Bearing Tube Remover/Installer with the Bearing Tube Removal Screw, Transmission Bearing Collet Remover/Installer and the Bearing Collet Sleeve Remover, remove the input shaft pocket bearing.
- Inspect the bearing for wear or damage. Install a new bearing as necessary.
  
  Fig 5: Removing Input Shaft Pocket Bearing
  Courtesy of FORD MOTOR CO.
Remove and discard the snap ring.

Fig 6: Locating Snap Ring
Courtesy of FORD MOTOR CO.
Using the 2 or 3 Jaw Puller, Shaft Protector Set and the Bearing Puller, remove the 3rd and 4th synchronizer assembly and 3rd gear.
- Inspect 3rd gear for wear or damage. Install a new gear as necessary.
  
  Fig 7: Removing 3Rd And 4Th Synchronizer Assembly And 3Rd Gear
  Courtesy of FORD MOTOR CO.
Disassemble the 3rd and 4th synchronizer assembly.
- Inspect the components for wear or damage. Install new components as necessary.
  
  Fig 8: Disassembling 3Rd And 4Th Synchronizer Assembly
  Courtesy of FORD MOTOR CO.
Check the clearance between the synchronizer ring and the gear.
1. Place the synchronizer ring onto the synchronizer sliding sleeve. Position the synchronizer ring on the gear.
2. Insert a feeler gauge and measure the clearance, while applying pressure and rotating the synchronizer ring. The clearance should be the same around the entire circumference.
  - Place the feeler gauge between the ring and gear clutching teeth. The ring has a raised section, inserting the feeler gauge past the teeth will give an incorrect reading.
  - If the clearance is less than 1.0 mm (0.039 in), install a new synchronizer assembly.
    
    Fig 9: Checking Clearance Between Synchronizer Ring And Gear
    Courtesy of FORD MOTOR CO.
Remove the mainshaft needle bearing.
- Inspect the bearing for wear or damage. Install a new bearing as necessary.
  
  Fig 10: Locating Mainshaft Needle Bearing
  Courtesy of FORD MOTOR CO.

NOTE: When installing the Bearing Puller, make sure it is installed above the mainshaft bearing race.

Fig 11: Pressing Mainshaft Gear Bushing Off Mainshaft

Courtesy of FORD MOTOR CO.

Using the 17.5 Ton Press and the Bearing Puller, press the mainshaft gear bushing off the mainshaft.
Using the 17.5 Ton Press and the Bearing Puller, press the mainshaft 2nd gear thrust washer, the mainshaft 2nd gear, the mainshaft needle bearing, the mainshaft gear bushing, 1st and 2nd synchronizer assembly and mainshaft 1st gear.
- Inspect the gears and bearing for wear or damage. Install new components as necessary.
  
  Fig 12: Pressing 1St And 2Nd Synchronizer Assembly
  Courtesy of FORD MOTOR CO.
Remove the mainshaft 1st gear needle bearing.
- Inspect the bearing for wear or damage. Install a new bearing as necessary.
  
  Fig 13: Removing Mainshaft 1St Gear Needle Bearing
  Courtesy of FORD MOTOR CO.
Using the 17.5 Ton Press and the Bearing Puller, remove the mainshaft center bearing.
- Inspect the bearing for wear or damage. Install a new bearing as necessary.
  
  Fig 14: Removing Mainshaft Center Bearing
  Courtesy of FORD MOTOR CO.
Disassemble the 1st and 2nd synchronizer assembly.
- Inspect the components for wear or damage. Install a new synchronizer assembly as necessary.
  
  Fig 15: Disassembling First And Second Synchronizer Assembly
  Courtesy of FORD MOTOR CO.
Check the clearance between the synchronizer ring and the gear clutching teeth.
1. Place the synchronizer ring onto the synchronizer sliding sleeve. Position the synchronizer ring on the gear.
2. Insert a feeler gauge and measure the clearance, while applying pressure and rotating the synchronizer ring. The clearance should be the same around the entire circumference.
  - Place the feeler gauge between the ring and gear clutching teeth. The ring has a raised section, inserting the feeler gauge past the teeth will give an incorrect reading.
  - If the clearance is less than 1.0 mm (0.039 in), install a new synchronizer assembly.
    
    Fig 16: Checking Clearance Between Synchronizer Ring And Gear
    Courtesy of FORD MOTOR CO.

NOTE: To prevent damage, do not heat bearings, thrust washers, bushings or the synchronizer bodies higher than 150°C (302°F).

New or original components should be heated in advance of the assembly procedure. Heating the specified components will ease the assembly process. Place the input shaft pocket bearing, the mainshaft second gear thrust washer, the mainshaft center bearing, the synchronizer bodies and the mainshaft gear bushings into the Gear/Bearing Heater.