Input Shaft: Assembly

WARNING: This page is about a different car, the 2011 Mercury Milan and 2011 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Do not reassemble the input shaft dry.

Lubricate all input shaft components with the recommended transmission lubricant during reassembly.

NOTE: Use the Shaft Protector Set to prevent damage to the shaft.

Fig 1: Pressing New Bearing Using Bearing/Oil Seal Plate And Transaxle Bearing Cone Installer

Courtesy of FORD MOTOR CO.

Using the Bearing/Oil Seal Plate, Transaxle Bearing Cone Installer and a suitable press, press on the new bearing.
Install 3rd gear.
Assemble 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 Components
  Courtesy of FORD MOTOR CO.
Assemble 3rd gear blocking ring set and synchronizer assembly

NOTE: Use the Shaft Protector Set to prevent damage to the shaft.

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.

NOTE: Make sure 3rd gear rotates freely on the shaft.

Fig 3: Pressing Input Shaft Onto 3rd Gear Synchronizer Blocking Ring And Synchronizer Assembly

Courtesy of FORD MOTOR CO.

Using the Bearing/Oil Seal Plate, Differential Bearing Cup Installer and a suitable press, press the input shaft onto the 3rd gear synchronizer blocking ring and synchronizer assembly.

NOTE: Invert the input shaft.

Fig 4: Locating Snap Ring

Courtesy of FORD MOTOR CO.

Install a new snap ring.
Assemble the 4th gear blocking ring set.
Assemble the 4th gear synchronizer assembly.
Install the 4th gear blocking ring set and synchronizer assembly into the input shaft.

NOTE: Press the bearing onto the input shaft by the inner race only. Pressing on the outer race will damage the bearing.

NOTE: Make sure 4th gear rotates freely on the shaft.

NOTE: When installing the synchronizer blocking ring, align the synchronizer blocking ring tab and synchronizer hub inserts.

NOTE: Using the Bearing Puller and a suitable press, press on a new bearing.

Fig 5: Pressing New Bearing Using Bearing Puller And Suitable Press

Courtesy of FORD MOTOR CO.

NOTE: If not within specifications, disassemble and reassemble the input shaft assembly.

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 (0.02 in).
2. Measure the clearance between the 4th gear and the bearing cone.
  - 4th gear end play is 0.17-0.37 mm (0.006-0.014 in), maximum end play is 0.42 mm (0.016 in).
  Fig 6: Identifying Input Shaft And Bearing Cone
  Courtesy of FORD MOTOR CO.