Idler Gear: Assembly

Clean the components with a suitable solvent and use compressed air to dry all parts. Perform the following before assembly:
- Inspect idler gear for damaged or excessively worn teeth.
- Inspect the idler gear shaft for damage or wear.
Use Pinion Bearing Cup Replacer to press the new bearing cups into the idler gear.

Fig 1: Installing Bearing Cup
Courtesy of FORD MOTOR CO.
Install a new (A) idler gear bearing onto the idler gear shaft, then install the (B) idler gear, (C) spacer, and the other new (D) idler gear bearing.

Fig 2: Installing Idler Gear Bearing Onto Idler Gear Shaft
Courtesy of FORD MOTOR CO.

CAUTION: Use protective vise plates to prevent damage to the special tool.

Fig 3: Securing Idler Gear Shaft In Vise

Courtesy of FORD MOTOR CO.

Use Torque Adapter to secure the idler gear shaft in the vise.
Use (A) Mainshaft Locknut Wrench along with a (B) 1-5/8 inch socket and install the idler gear shaft nut.

Fig 4: Installing Idler Gear Shaft Nut
Courtesy of FORD MOTOR CO.
Apply Motorcraft MERCON® Multi-Purpose Automatic Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON to a new idler gear shaft seal and install it on the idler gear shaft.
- Idler gear shaft seal inner diameter: 40.5 mm (1.594 in).
Fig 5: Applying Multi-Purpose Automatic Transmission Fluid
Courtesy of FORD MOTOR CO.

CAUTION: Use protective vise plates to prevent damage to the idler gear.

NOTE: Take several measurements and calculate the average value.

Fig 6: Measuring Preload

Courtesy of FORD MOTOR CO.

Measure the idler gear shaft preload.
- Turn the idler gear and Torque Adapter over and secure the idler gear in a vise. Measure the preload when the idler gear shaft begins to rotate.

NOTE: The preload can be reduced by increasing the thickness of the spacer (adjusting shims).

If the specified preload cannot be obtained within the specified idler gear shaft nut torque, adjust it by selecting the proper spacer from the figure below.