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Input Shaft: Disassembly

Fig 1: Exploded View Of Input Shaft
G01372455Courtesy of FORD MOTOR CO.
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 2: Measuring Input Shaft Clearances
    G01372456Courtesy of FORD MOTOR CO.
  2. Use an (A) arbor press, (B) Shaft Protector, and (C) Bearing Pulling Attachment to press off the (D) bearing (fourth gear end).
    Fig 3: Installing Bearing Pulling Attachment
    G01372457Courtesy of FORD MOTOR CO.
    3. CAUTION: The synchronizer blocking rings are not interchangeable. Be sure to keep them in the order that they were removed.
  3. Remove fourth gear and the synchronizer blocking ring.
  4. Remove the snap ring.
    Fig 4: Removing Snap Ring
    G01372458Courtesy of FORD MOTOR CO.
    5. CAUTION: The synchronizer blocking rings are not interchangeable. Be sure to keep them in the order that they were removed.
    NOTE: Inspect all the synchronizer components for wear and damage; refer to SYNCHRONIZERS .
    Fig 5: Pressing Off Synchronizer Hub Assembly, Synchronizer Blocking Ring And Third Gear
    G01372459Courtesy of FORD MOTOR CO.
  5. Use an (A) arbor press, (B) Shaft Protector, and (C) Pinion Bearing Cone Remover to press off the (D) synchronizer hub assembly, (E) synchronizer blocking ring, and (F) third gear.
  6. Use an arbor press, (A) Shaft Protector, and (B) Bearing Pulling Attachment to press off the (C) bearing (third gear end).
    Fig 6: Pressing Off Bearing
    G01372460Courtesy of FORD MOTOR CO.
  7. Use Dial Indicator/Magnetic Base to measure input shaft gear runout.
    • Inspect the input shaft for worn or damaged gears.
    Fig 7: Measuring Input Shaft Gear Runout
    G01372461Courtesy of FORD MOTOR CO.
    8. NOTE: Set the synchronizer ring squarely in the gear, then measure around the circumference.
    Fig 8: Inspecting Synchronizer Blocking Rings
    G01372462Courtesy of FORD MOTOR CO.
  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.
  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 Third/Fourth Synchronizer Hub And Shift Fork
    G01372463Courtesy of FORD MOTOR CO.
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