Input Shaft: Assembly

WARNING: This page is about a different car, the 2010 Mercury Milan and 2010 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.
Using the Bearing/Oil Seal Plate, Transaxle Bearing Cone Installer and a suitable press, press on the new bearing.
NOTE: Use the Shaft Protector Set to prevent damage to the shaft.

Fig 1: Pressing Bearing
Courtesy of FORD MOTOR CO.
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
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: 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 & Synchronizer Assembly
Courtesy of FORD MOTOR CO.
Install a new snap ring.
NOTE: Invert the input shaft.

Fig 4: Locating Snap Ring
Courtesy of FORD MOTOR CO.
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.
Using the Bearing Puller and a suitable press, press on a new bearing.
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.

Fig 5: Pressing Bearing With Bearing Puller
Courtesy of FORD MOTOR CO.
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).
NOTE: If not within specifications, disassemble and reassemble the input shaft assembly.

Fig 6: Measuring Clearance Between 4th Gear & Bearing Cone
Courtesy of FORD MOTOR CO.