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Input Shaft: Disassembly

  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).
    2. Fig 1: Identifying Clearance Between 3rd And 2nd Gears And Between 4th Gear And Bearing Cone
    GF0029997Courtesy of FORD MOTOR CO.
    NOTE: 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.
    3. Fig 2: Identifying Bearing And Special Tool (205-D064)
    GF0029998Courtesy of FORD MOTOR CO.
    NOTE: The synchronizer blocking rings are not interchangeable. Make sure to keep them in the order that they were removed.
  3. Remove 4th gear and the synchronizer blocking ring.
    4. Fig 3: Locating 4th Gear And Synchronizer Blocking Ring
    GF0029999Courtesy of FORD MOTOR CO.
  4. Remove and discard the snap ring.
    5. Fig 4: Locating Snap Ring
    GF0030000Courtesy of FORD MOTOR CO.
    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.
    6. Fig 5: Locating Synchronizer Hub Assembly
    GF0030001Courtesy 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.
    7. Fig 6: Disassembled View Of Synchronizers
    GF0003967Courtesy 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.
    8. Fig 7: Identifying Special Tool (205-D064) And Bearing
    GF0030002Courtesy 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).
    9. Fig 8: Measuring Input Shaft Gear Runout
    GF0030003Courtesy 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.
    10. Fig 9: Measuring Clearance From Side Of Gear
    GF0030004Courtesy 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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