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Input Shaft: Disassembly

  1. Measure the input shaft clearances.
    1. Measure the clearance between the 3rd and 2nd gears. Third gear thrust clearance is 0.05-0.20 mm (0.001-0.007 in).
    2. Measure the clearance between 4th gear and the bearing cone. Fourth gear endplay is 0.17-0.37 mm (0.006-0.014 in).
      Fig 1: Identifying Input Shaft And Bearing Cone
      G08024554Courtesy of FORD MOTOR CO.
    2. NOTE: When pressing off components, hold the shaft so it does not fall.
    NOTE: Use the Shaft Protector Set to prevent damage to the shaft.
  2. Using the Bearing Puller and a suitable press, press off the bearing.
    • Discard the bearing.
    • Always install new bearings and cups as a set.
      Fig 2: Pressing Bearing Using Press
      G08024555Courtesy of FORD MOTOR CO.
    3. NOTE: The synchronizer blocking rings are not interchangeable. Make sure to keep them in the order that they were removed.
    Fig 3: Locating 4th Gear And Synchronizer Blocking Ring
    G08024556Courtesy of FORD MOTOR CO.
  3. Remove 4th gear and the synchronizer blocking ring.
  4. Remove and discard the snap ring.
    Fig 4: Locating Snap Ring
    G08024557Courtesy of FORD MOTOR CO.
    5. NOTE: The synchronizer blocking rings are not interchangeable. Make sure to keep them in the order that they were removed.
    NOTE: Use the Shaft Protector Set to prevent damage to the shaft.
    Fig 5: Pressing Off Synchronizer Hub Assembly, Blocking Ring And 3rd Gear Using Bearing Puller And Press
    G08024558Courtesy of FORD MOTOR CO.
    NOTE: Using a paint pen, mark the hub to sleeve position for reassembly.
  5. Using the Bearing Puller and a suitable press, press off the synchronizer hub assembly, the synchronizer blocking ring and 3rd gear as an assembly.
  6. Disassemble the synchronizer assembly.
    1. Remove the synchronizer blocking spring.
    2. Remove the opposite synchronize spring.
    3. Remove the synchronizer hub inserts.
    4. Separate the synchronizer hub from the sleeve.
      • Inspect all synchronizer components for wear and damage. Install a new synchronizer as necessary.
        Fig 6: Disassembled View Of Synchronizers
        G08024559Courtesy of FORD MOTOR CO.
    7. NOTE: Use the Shaft Protector Set to prevent damage to the shaft.
  7. Using the Bearing Puller and a suitable press, press off the bearing.
    • Discard the bearing.
    • Always install new bearings and cups as a set.
      Fig 7: Pressing Off Bearing Using Bearing Puller And Suitable Press
      G08024560Courtesy of FORD MOTOR CO.
  8. Using the Dial Indicator Gauge with Holding Fixture, measure the input shaft gear runout.
    • Inspect the input shaft for worn or damaged gears. Install a new input shaft as necessary.
    • Input shaft gear maximum runout is 0.05 mm (0.001 in).
      Fig 8: Measuring Input Shaft Gear Runout Using Dial Indicator Gauge (100-002)
      G08024561Courtesy of FORD MOTOR CO.
  9. Set the synchronizer ring set squarely on the gear, then measure around the circumference.
    • Measure the clearance from the side of the gear.
      • Synchronizer ring clearance is 0.80-1.50 mm (0.031-0.059 in).
    • Inspect for smooth engagement with the gear.
    • Inspect for worn or damaged teeth. Install new components as necessary.
      Fig 9: Measuring Clearance From Side Of Gear
      G08024562Courtesy of FORD MOTOR CO.
  10. Inspect the synchronizer hub.
    • Inspect for worn or damaged splines, synchronizer insert groove or end surface.
    • Inspect for smooth hub sleeve movement when it is installed.
  11. Measure the clearance between the 3rd/4th synchronizer hub and its shift fork.
    • Shift fork and hub sleeve clearance is 0.10-0.90 mm (0.003-0.035 in).
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