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Input Shaft: Disassembly

CAUTION: When pressing off components, hold the shaft so that it does not fall
  1. Measure the input shaft clearances.
    1. Measure the clearance between the third and second gears.
    2. Measure the clearance between fourth gear and the bearing cone.
      Fig 1: Measure Input Shaft Clearances
      G01391474Courtesy of FORD MOTOR CO.
  2. Using the special tools and a press, press off the bearing (fourth gear end).
    Fig 2: Pressing Bearing Using Special Tool
    G01391475Courtesy of FORD MOTOR CO.
    3. CAUTION: The synchronizer blocking rings are not interchangeable. Make sure to keep them in the order that they were removed.
    Fig 3: Locating Synchronizer Blocking Ring
    G01391476Courtesy of FORD MOTOR CO.
  3. Remove fourth gear and the synchronizer blocking ring.
  4. Remove the snap ring.
    Fig 4: Locating Snap Ring
    G01391477Courtesy of FORD MOTOR CO.
    5. CAUTION: The synchronizer blocking rings are not interchangeable. Make sure to keep them in the order that they were removed.
    NOTE: Inspect all the synchronizer components for wear and damage; refer to SYNCHRONIZERS - FIRST/SECOND AND THIRD/FOURTH GEARS  for Vehicles Built After 3/2002 in this article.
    Fig 5: Pressing Off Synchronizer Hub Assembly Using Special Tool
    G01391478Courtesy of FORD MOTOR CO.
  5. Using the special tools and a press, press off the synchronizer hub assembly, synchronizer blocking ring, and third gear.
  6. Using the special tools and a press, press off the bearing (third gear end).
    Fig 6: Press Off Bearing (Third Gear End) Using Special Tool
    G01391479Courtesy of FORD MOTOR CO.
  7. Measure input shaft gear runout.
    • Inspect the input shaft for worn or damaged gears.
      Fig 7: Inspecting Input Shaft
      G01391480Courtesy of FORD MOTOR CO.
    8. NOTE: Set the synchronizer ring squarely in the gear, then measure around the circumference.
  8. Inspect the synchronizer blocking rings.
    • Measure the clearance from the side of the gear.
    • Inspect for smooth engagement with the gear.
    • Inspect for worn or damaged teeth or tapper surface.
      Fig 8: Inspecting Synchronizer Blocking Rings
      G01391481Courtesy of FORD MOTOR CO.
  9. 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.
  10. Measure the clearance between the third/fourth synchronizer hub and its shift fork.
    Fig 9: Measuring Clearance Between Synchronizer Hub And Its Shift Fork
    G01391482Courtesy of FORD MOTOR CO.
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