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Input Shaft: Assembly

  1. Using the special tools, install the input shaft front bearing.
    Fig 1: Installing Input Shaft Front Bearing
    G03901779Courtesy of FORD MOTOR CO.
  2. Install the 3rd gear needle bearing.
  3. Install the 3rd input gear.
  4. Install the 3rd gear synchronizer ring.
    5. CAUTION: Make sure the synchronizer side with 3 notches is facing the 3rd input gear and the synchronizer side with 4 notches is facing the 4th gear.
    Fig 2: Installing New 3rd And 4th Gear Synchronizer Assembly
    G03901780Courtesy of FORD MOTOR CO.
  5. Install a new 3rd and 4th gear synchronizer assembly.
  6. Install the 4th gear synchronizer ring.
  7. Using the special tools, install the 4th gear bushing.
    Fig 3: Installing 4th Gear Bushing
    G03901781Courtesy of FORD MOTOR CO.
  8. Install the 4th gear needle bearing.
  9. Install the 4th input gear.
    10. CAUTION: Only one thrust washer can be selected.
    Fig 4: Measuring Distance
    G03901782Courtesy of FORD MOTOR CO.
  10. Select the correct thickness thrust washer.
    • Measure the distance as shown in Fig 4.
    • If the measurement is not within 154.7 - 154.8 mm (6.090 - 6.094 in), select the correct thickness of shim from the following chart:
    SHIM THICKNESS SPECIFICATIONS

    mm in
    3.84 0.151
    3.90 0.153
    3.96 0.155
    4.02 0.158
    4.08 0.16
    4.14 0.162
  11. Using the special tools, install the thrust washer.
    Fig 5: Installing Thrust Washer
    G03901783Courtesy of FORD MOTOR CO.
  12. Using the special tools, install a new 5th gear bushing.
    Fig 6: Installing New 5th Gear Bushing
    G03901784Courtesy of FORD MOTOR CO.
  13. Install the 5th gear needle bearing.
  14. Install the 5th input gear.
  15. Install a new 5th gear synchronizer ring.
    16. CAUTION: Make sure the synchronizer side with the 3 notches is facing the 4th input gear.
    Fig 7: Installing New 5th Gear Synchronizer Assembly
    G03901785Courtesy of FORD MOTOR CO.
  16. Install a new 5th gear synchronizer assembly.
  17. Using the special tools, install the 5th gear stopper and input shaft bearing spacer together.
    Fig 8: Installing 5th Gear Stopper And Input Shaft Bearing Spacer Together
    G03901786Courtesy of FORD MOTOR CO.
  18. Install the input shaft spacer.
  19. Measure the gap between the snap ring groove and the snap ring. The end play should be between 0 - 0.1 mm (0 - 0.0039 in). Refer to SNAP RING THICKNESS SPECIFICATIONS  for the correct snap ring thickness:
    SNAP RING THICKNESS SPECIFICATIONS

    mm in
    1.71 0.067
    1.76 0.069
    1.81 0.071
    1.86 0.073
    1.91 0.075
    1.96 0.077
    2.01 0.079
    2.06 0.081
    2.11 0.083
    2.16 0.085
    2 21 0.087
    2.26 0.088
    Fig 9: Measuring Gap Between Snap Ring Groove And Snap Ring
    G03901787Courtesy of FORD MOTOR CO.
  20. Using the special tools, install the input shaft rear bearing.
    Fig 10: Installing Input Shaft Rear Bearing
    G03901788Courtesy of FORD MOTOR CO.
  21. Install the oil channel.
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