Input Shaft: Disassembly

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.

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: Measuring Clearance Between 4th Gear & Bearing Cone
Courtesy of FORD MOTOR CO.
Using the Bearing Puller and a suitable press, press off the bearing.
- Discard the bearing.
- Always install new bearings and cups as a set.
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.

Fig 2: Pressing Bearing
Courtesy of FORD MOTOR CO.
Remove 4th gear and the synchronizer blocking ring.
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 & Synchronizer Blocking Ring
Courtesy of FORD MOTOR CO.
Remove and discard the snap ring.

Fig 4: Locating Discard Snap Ring
Courtesy of FORD MOTOR CO.
Using the Bearing Puller and a suitable press, press off the synchronizer hub assembly, the synchronizer blocking ring and 3rd gear as an assembly.
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 Synchronizer Hub Assembly
Courtesy of FORD MOTOR CO.

NOTE: Using a paint pen, mark the hub to sleeve position for reassembly.
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 Assembly
Courtesy of FORD MOTOR CO.
Using the Bearing Puller and a suitable press, press off the bearing.
NOTE: Use the Shaft Protector Set to prevent damage to the shaft.
- Discard the bearing.
- Always install new bearings and cups as a set.
Fig 7: Pressing Bearing
Courtesy of FORD MOTOR CO.
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
Courtesy of FORD MOTOR CO.
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
Courtesy of FORD MOTOR CO.
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.
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).