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Input Shaft: Disassembly

WARNING: This page is about a different car, the 2006 Mercury Milan and 2006 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
  1. 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 (0.002-0.007 in).
    2. Measure the clearance between 4th gear and the bearing cone. Fourth gear endplay is 0.17-0.37 mm (0.007-0.014 in).
      Fig 1: Identifying Clearance Between 3Rd And 2Nd Gears And Between 4Th Gear And Bearing Cone
      G04682171Courtesy of FORD MOTOR CO.
    2. CAUTION: When pressing off components, hold the shaft so that it does not fall.
  2. Using the special tool, press off the bearing.
    • Use shaft protector 205-DS004 or equivalent.
    • Discard the bearing.
    • Always install new bearings and cups as a set. Do not install one without the other.
      Fig 2: Identifying Bearing And Special Tool!
      G04682172Courtesy 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 4Th Gear And Synchronizer Blocking Ring
    G04682173Courtesy of FORD MOTOR CO.
  3. Remove 4th gear and the synchronizer blocking ring.
  4. Remove and discard the snap ring.
    Fig 4: Locating Snap Ring
    G04682174Courtesy 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.
  5. Using the special tool, press off the synchronizer hub assembly, the synchronizer blocking ring and 3rd gear as an assembly.
    • Use shaft protector 205-DS004 or equivalent.
      Fig 5: Locating Synchronizer Hub Assembly
      G04682175Courtesy of FORD MOTOR CO.
  6. 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: Disassembling Synchronizer Assembly
        G04682176Courtesy of FORD MOTOR CO.
  7. Using the special tool, press off the bearing.
    • Use shaft protector 205-DS004 or equivalent.
    • Discard the bearing.
    • Always install new bearings and cups as a set. Do not install one without the other.
      Fig 7: Identifying Special Tool And Bearing
      G04682177Courtesy of FORD MOTOR CO.
  8. 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 runout is 0.05 mm (0.002 in).
      Fig 8: Measuring Input Shaft Gear Runout
      G04682178Courtesy of FORD MOTOR CO.
  9. Set the synchronizer ring squarely in the gear, then measure around the circumference.
    • Measure the clearance from the side of the gear.
      • Synchronizer ring clearance is 0.080-1.50 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
      G04682179Courtesy of FORD MOTOR CO.
  10. 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.
  11. Measure the clearance between the 3rd/4th synchronizer hub and its shift fork.
    • Shift fork and hub sleeve clearance is 0.10-0.45 mm (0.004-0.017 in).
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