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Input Shaft: Assembly

WARNING: This page is about a different car, the 2006 Mercury Milan and 2006 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Do not reassemble the input shaft dry.
  1. Lubricate all input shaft components with the recommended transmission lubricant during reassembly.
  2. Using the special tool, press on the new bearing.
    Fig 1: Identifying Special Tools And New Bearing
    G04682180Courtesy of FORD MOTOR CO.
  3. Install 3rd gear.
  4. Assembly the synchronizer.
    1. Position the synchronizer hub and sleeve together.
    2. Install the synchronizer hub inserts.
    3. Install the synchronizer blocking spring.
    4. Rotate the synchronizer and install the opposite synchronizer blocking spring.
      Fig 2: Identifying Synchronizer Hub Assembly
      G04682181Courtesy of FORD MOTOR CO.
    5. NOTE: When installing the synchronizer blocking ring, align the synchronizer blocking ring groove and synchronizer hub inserts.
    NOTE: Make sure to have the ridge facing the 3rd gear when installing the synchronizer hub assembly.
    NOTE: Make sure that the 4 grooves in the synchronizer hub are facing the 3rd gear.
    Fig 3: Identifying Special Tools
    G04682182Courtesy of FORD MOTOR CO.
  5. Using the special tools, press on the synchronizer blocking ring and synchronizer hub assembly.
    6. NOTE: Rotate the input shaft.
    Fig 4: Locating Snap Ring
    G04682183Courtesy of FORD MOTOR CO.
  6. Install a new snap ring.
    7. CAUTION: Press the bearing onto the input shaft by the inner race only. Pressing on the outer race will damage the bearing.
    NOTE: Rotate the input shaft.
    NOTE: When installing the synchronizer blocking ring, align the synchronizer blocking ring groove and synchronizer hub inserts.
    Fig 5: Identifying Special Tools
    G04682184Courtesy of FORD MOTOR CO.
  7. Using the special tools, press on the synchronizer blocking ring, 4th gear and a new bearing.
    8. NOTE: If not within specifications, disassemble and reassemble the input shaft assembly.
  8. Measure the input shaft clearances.
    1. Measure the clearance between the 3rd and 2nd gears.
      • 2nd gear end play is 0.018-0.46 mm (0.007-0.018 in) maximum end play is 0.51 mm (0.020 in).
    2. Measure the clearance between the 4th gear and the bearing cone.
      • 4th gear end play is 0.17-0.37 mm (0.007-0.014 in) maximum end play is 0.42 mm (0.017 in).
        Fig 6: Identifying Clearance Between 3Rd And 2Nd Gears And Between 4Th Gear And Bearing Cone
        G04682185Courtesy of FORD MOTOR CO.
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