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Input Shaft: Assembly

  1. Using the Input Bearing Installer and the Spindle/Axle Shaft Installer with the Bearing Puller, press on the input shaft front bearing.
    Fig 1: Pressing Input Shaft Front Bearing Using Special Tools
    G06098244Courtesy 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. NOTE: 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: Identifying Gear Synchronizer Assembly
    G06098245Courtesy of FORD MOTOR CO.
  5. Install a new 3rd and 4th gear synchronizer assembly.
  6. Install the 4th gear synchronizer ring.
  7. Using the Spindle/Axle Shaft Installer with the Bearing Puller, press on the 4th gear bushing.
    Fig 3: Pressing 4th Gear Bushing Using Special Tools
    G06098246Courtesy of FORD MOTOR CO.
  8. Install the 4th gear needle bearing.
  9. Install the 4th input gear.
    10. NOTE: Only one thrust washer can be selected.
    Fig 4: Identifying Correct Thickness Of Shim
    G06098247Courtesy of FORD MOTOR CO.
  10. Select the correct thickness thrust washer.
    • Measure the distance as shown in illustration.
    • If the measurement is not within 154.7-154.8 mm (6.09-6.094 in), select the correct thickness of shim from the following chart:
    THICKNESS SPECIFICATION

    mm Inch
    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 Spindle/Axle Shaft Installer with the Bearing Puller, press on the thrust washer.
    Fig 5: Pressing Thrust Washer Using Special Tools
    G06098248Courtesy of FORD MOTOR CO.
  12. Using the Spindle/Axle Shaft Installer with the Bearing Puller, press on a new 5th gear bushing.
    Fig 6: Pressing 5th Gear Bushing Using Special Tools
    G06098249Courtesy 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. NOTE: Make sure the synchronizer side with the 3 notches is facing the 4th input gear.
    Fig 7: Identifying 5th Gear Synchronizer Assembly
    G06098250Courtesy of FORD MOTOR CO.
  16. Install a new 5th gear synchronizer assembly.
  17. Using the Spindle/Axle Shaft Installer with the Bearing Puller, press on the 5th gear stopper and input shaft bearing spacer together.
    Fig 8: Pressing 5th Gear Stopper And Input Shaft Bearing Spacer Together Using Special Tools
    G06098251Courtesy of FORD MOTOR CO.
  18. Install the input shaft spacer.
  19. Install new snap ring. Measure the gap between the snap ring groove and the snap ring. The end play should be between 0-0.1 mm (0-0.003 in). Refer to the following chart for the correct snap ring thickness:
    THICKNESS SPECIFICATION

    mm Inch
    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
    G06098252Courtesy of FORD MOTOR CO.
  20. Using the Input Bearing Installer and the Spindle/Axle Shaft Installer with the Bearing Puller, press on the input shaft rear bearing.
    Fig 10: Pressing Input Shaft Rear Bearing Using Special Tools
    G06098253Courtesy of FORD MOTOR CO.
  21. Install the oil channel.
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