Disassembly And Assembly Of Subassemblies: Mainshaft: Assembly

WARNING: This page is about a different car, the 2006 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: Be careful with the orientation of the reverse main gear.

Fig 1: Locating Reverse Main Gear On Mainshaft

Courtesy of FORD MOTOR CO.

Position the reverse main gear on the mainshaft.
Using the special tool, install a new reverse main gear.

Fig 2: Installing Reverse Main Gear
Courtesy of FORD MOTOR CO.
Install the 1st main gear.
Using the special tools, install the 1st main gear bushing.

Fig 3: Installing Main Gear Bushing Using Special Tools
Courtesy of FORD MOTOR CO.
Install the 1st gear needle bearing.
Install the 1st gear synchronizer ring.

NOTE: Make sure the synchronizer side with 3 notches is facing 1st gear and the synchronizer side with 4 notches is facing 2nd gear.

Fig 4: Identifying 1st And 2nd Gear Synchronizer With Notches

Courtesy of FORD MOTOR CO.

Position a new 1st and 2nd gear synchronizer assembly on the mainshaft.
Using the special tools, install the 1st and 2nd gear synchronizer assembly.

Fig 5: Installing Gear Synchronizer Assembly Using Special Tool
Courtesy of FORD MOTOR CO.
Install the 2nd gear synchronizer ring.
Using the special tools, install the 2nd gear bushing.

Fig 6: Installing Gear Bushing Using Special Tools
Courtesy of FORD MOTOR CO.
Install the 2nd gear needle bearing.
Install the 2nd main gear.

NOTE: Be careful with the orientation of the 3rd main gear.

Fig 7: Installing Main Gear Using Special Tools

Courtesy of FORD MOTOR CO.

Using the special tools, install a new 3rd main gear.
Install the 3rd/4th main gear shaft spacer.

NOTE: Only one adjusting shim can be installed.

Fig 8: Measuring Mainshaft Components

Courtesy of FORD MOTOR CO.

Measure the mainshaft components as indicated to select the appropriate 4th main gear adjusting shim. Refer to the following table for shim thicknesses and install the 4th main gear adjusting shim:

SHIM THICKNESSES CHART

mm	Inch
0.52	0.021
0.60	0.024
0.68	0.027
0.76	0.030
0.84	0.033
0.92	0.036
1.00	0.039
1.08	0.043

NOTE: Be careful with the orientation of the 4th main gear.

Fig 9: Installing New 4th Main Gear Using Special Tool

Courtesy of FORD MOTOR CO.

Using the special tool, install a new 4th main gear.

NOTE: Be careful with the orientation of the 5th main gear.

Fig 10: Installing New 5th Main Gear Using Special Tool

Courtesy of FORD MOTOR CO.

Using the special tool, install a new 5th main gear.

Measure the gap between the snap ring and the 5th main gear. The end play should be less than 0.1 mm (0.0039 in). Refer to the following chart to select the appropriate snap ring thickness and install a new snap ring:

SNAP RING THICKNESS CHART

mm	Inch
1.85	0.073
1.90	0.075
1.95	0.077
2.00	0.079
2.05	0.081
2.10	0.083
2.15	0.085
2.20	0.087

Fig 11: Measuring Gap Between Snap Ring And Main Gear

Courtesy of FORD MOTOR CO.

NOTE: Be careful with the orientation of the mainshaft rear bearing.

Fig 12: Installing Mainshaft Rear Bearing

Courtesy of FORD MOTOR CO.

Using the special tool, install the mainshaft rear bearing.

Measure the gap between the mainshaft C-ring and the mainshaft rear bearing. Refer to the following chart to select the appropriate C-ring thickness and install the C-ring:

C-RING THICKNESS CHART

mm	Inch
2.535	0.0998
2.565	0.1010
2.595	0.1022
2.625	0.1033
2.655	0.1045
2.685	0.1057
2.715	0.1069
2.745	0.1081
2.775	0.1093
2.805	0.1104
2.835	0.1116
2.865	0.1128
2.895	0.1140
2.925	0.1152
2.955	0.1163
2.985	0.1175
3.015	0.1187
3.045	0.1199
3.075	0.1211

Fig 13: Measuring Gap Between Mainshaft C-Ring And Mainshaft Rear Bearing

Courtesy of FORD MOTOR CO.

Install the C-ring holder.
Install a new snap ring.