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Input Shaft: 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.
  1. Using the special tools, install the input shaft front bearing.
    Fig 1: Installing Input Shaft Front Bearing Using Special Tool
    G04620996Courtesy of FORD MOTOR CO.
  2. Install the 3rd gear needle bearing.
  3. Install the 3rd input gear.
  4. Install the 3rd gear synchronizer ring.
    5. NOTE: Make sure the synchronizer side with 3 notches is facing the 3rd input gear and the synchronizer side with 4 notches is facing the 4th gear.
    Fig 2: Identifying Synchronizer Assembly
    G04620997Courtesy of FORD MOTOR CO.
  5. Install a new 3rd and 4th gear synchronizer assembly.
  6. Install the 4th gear synchronizer ring.
  7. Using the special tools, install the 4th gear bushing.
    Fig 3: Identifying Special Tool And Gear Bushing
    G04620998Courtesy of FORD MOTOR CO.
  8. Install the 4th gear needle bearing.
  9. Install the 4th input gear.
    10. NOTE: Only one thrust washer can be selected.
    Fig 4: Identifying Measurement
    G04620999Courtesy of FORD MOTOR CO.
  10. Select the correct thickness thrust washer.
    • Measure the distance as shown.
    • If the measurement is not within 154.7-154.8 mm (6.090-6.094 in), select the correct thickness of shim from the following chart:
    THRUST WASHER THICKNESS CHART

    mm Inch
    3.84 0.151
    3.90 0.153
    3.96 0.155
    4.02 0.158
    4.08 0.16
    4.14 0.162
  11. Using the special tools, install the thrust washer.
    Fig 5: Installing Thrust Washer Using Special Tool
    G04621000Courtesy of FORD MOTOR CO.
  12. Using the special tools, install a new 5th gear bushing.
    Fig 6: Installing 5th Gear Bushing Using Special Tool
    G04621001Courtesy of FORD MOTOR CO.
  13. Install the 5th gear needle bearing.
  14. Install the 5th input gear.
  15. Install a new 5th gear synchronizer ring.
    16. NOTE: Make sure the synchronizer side with the 3 notches is facing the 4th input gear.
    Fig 7: Identifying Synchronizer Side With Notches
    G04621002Courtesy of FORD MOTOR CO.
  16. Install a new 5th gear synchronizer assembly.
  17. Using the special tools, install the 5th gear stopper and input shaft bearing spacer together.
    Fig 8: Installing 5th Gear Stopper And Input Shaft Rear Bearing Spacer Using Special Tool
    G04621003Courtesy of FORD MOTOR CO.
  18. Install the input shaft spacer.
  19. Install new snap ring. Measure the gap between the snap ring groove and the snap ring. The end play should be between 0-0.1 mm (0-0.0039 in). Refer to the following chart for the correct snap ring thickness:
    SNAP RING THICKNESS CHART

    mm Inch
    1.71 0.067
    1.76 0.069
    1.81 0.071
    1.86 0.073
    1.91 0.075
    1.96 0.077
    2.01 0.079
    2.06 0.081
    2.11 0.083
    2.16 0.085
    2.21 0.087
    2.26 0.088
    Fig 9: Measuring Gap Between Snap Ring Groove And Snap Ring
    G04621004Courtesy of FORD MOTOR CO.
  20. Using the special tools, install the input shaft rear bearing.
    Fig 10: Installing Input Shaft Rear Bearing
    G04621005Courtesy of FORD MOTOR CO.
  21. Install the oil channel.
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