Disassembly And Assembly Of Subassemblies: Mainshaft: Assembly

NOTE: Be careful with the orientation of the reverse main gear or damage to the component may occur.

Fig 1: Positioning Reverse Main Gear On Mainshaft

Courtesy of FORD MOTOR CO.

Position the reverse main gear on the mainshaft.
Using the Spindle/Axle Shaft Installer, press on a new reverse main gear.

Fig 2: Pressing Reverse Main Gear
Courtesy of FORD MOTOR CO.
Install the 1st main gear.
Using the Bearing/Oil Seal Plate and the Sixth Gear Bushing Installer, press on the 1st main gear bushing.

Fig 3: Installing 1st Main Gear Bushing
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 3rd And 4th Gear Synchronizer Assembly

Courtesy of FORD MOTOR CO.

Position a new 1st and 2nd gear synchronizer assembly on the mainshaft.
Using the Spindle/Axle Shaft Installer and the Bearing Puller, press on the 1st and 2nd gear synchronizer assembly.

Fig 5: Pressing 1st And 2nd Gear Synchronizer Assembly
Courtesy of FORD MOTOR CO.
Install the 2nd gear synchronizer ring.
Using the Bearing/Oil Seal Plate and the Second Gear Bushing Installer, press on the 2nd gear bushing.

Fig 6: Installing 2nd Gear Bushing
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 3rd Main Gear

Courtesy of FORD MOTOR CO.

Using the Spindle/Axle Shaft Installer and the Bearing Puller, press on 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 Select 4th Main Gear Adjusting Shim

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:

mm	Inch
0.52	0.02
0.60	0.023
0.68	0.026
0.76	0.029
0.84	0.033
0.92	0.036
1.00	0.039
1.08	0.042

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

Fig 9: Installing 4th Main Gear

Courtesy of FORD MOTOR CO.

Using the Spindle/Axle Shaft Installer, press on a new 4th main gear.

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

Fig 10: Installing 5th Main Gear

Courtesy of FORD MOTOR CO.

Using the Spindle/Axle Shaft Installer, press on 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:

mm	Inch
1.85	0.072
1.90	0.074
1.95	0.076
2.00	0.078
2.05	0.08
2.10	0.082
2.15	0.084
2.20	0.086

Fig 11: Measuring Gap Between Snap Ring And 5th 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 Spindle/Axle Shaft Installer, press on 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:

mm	Inch
2.535	0.099
2.565	0.1
2.595	0.102
2.625	0.103
2.655	0.104
2.685	0.105
2.715	0.106
2.745	0.108
2.775	0.109
2.805	0.11
2.835	0.111
2.865	0.112
2.895	0.113
2.925	0.115
2.955	0.116
2.985	0.117
3.015	0.118
3.045	0.119
3.075	0.121

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.