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Input Shaft: Disassembly

  1. Prior to disassembly of the input shaft, measure and record the end play for the 3rd, 4th and 5th gears. Refer to the following chart for standard values:
    GEAR SPECIFICATION CHART

    Gear mm Inch
    3rd 0.18-0.31 0.007-0.0122
    4th 0.20-0.30 0.0078-0.0118
    5th 0.06-0.16 0.0024-0.0063
    Fig 1: Measuring End Play For 3rd, 4th And 5th Gears
    G06098234Courtesy of FORD MOTOR CO.
  2. Remove the oil channel.
  3. Using the Bearing Puller and a suitable press, remove the input shaft rear bearing.
    Fig 2: Removing Input Shaft Rear Bearing Using Special Tool
    G06098235Courtesy of FORD MOTOR CO.
    4. NOTE: The snap ring is not reusable.
    Fig 3: Locating Snap Ring
    G06098236Courtesy of FORD MOTOR CO.
  4. Remove and discard the snap ring.
  5. Using the Bearing Puller and a suitable press, remove the input shaft spacer and the 5th gear stopper together.
    Fig 4: Removing Input Shaft Spacer And 5th Gear Stopper Together Using Special Tool
    G06098237Courtesy of FORD MOTOR CO.
  6. Using the Bearing Puller and a suitable press, remove the 5th gear synchronizer assembly, the 5th gear synchronizer ring and the 5th input gear together.
    • Discard the 5th gear synchronizer ring and assembly.
    Fig 5: Removing 5th Gear Synchronizer Assembly Using Special Tool
    G06098238Courtesy of FORD MOTOR CO.
  7. Remove the 5th gear needle bearing.
  8. Using the Bearing Puller and a suitable press, remove the 5th gear bushing, thrust washer, 4th input gear, 4th gear needle bearing, 4th gear bushing, 4th gear synchronizer ring, 3rd and 4th gear synchronizer assembly, 3rd gear synchronizer ring and 3rd input gear together.
    • Discard the 5th gear bushing.
    • Discard the 3rd and 4th gear synchronizer assembly.
    Fig 6: Removing 5th Gear Needle Bearing Using Special Tool
    G06098239Courtesy of FORD MOTOR CO.
  9. Remove the 3rd gear needle bearing.
  10. Using the Bearing Puller and a suitable press, remove the input shaft front bearing.
    Fig 7: Removing 3rd Gear Needle Bearing Using Special Tool
    G06098240Courtesy of FORD MOTOR CO.
  11. Inspect all input shaft parts for damage, peeling, dents, uneven wear or bending. Install new parts as necessary.
    Fig 8: Identifying Input Shaft Parts
    G06098241Courtesy of FORD MOTOR CO.
  12. Inspect the synchronizer rings for damage. Install new parts as necessary.
    Fig 9: Identifying Synchronizer Rings With Damage
    G06098242Courtesy of FORD MOTOR CO.
    13. NOTE: Limit value: 0.7 mm (0.027 in).
  13. Press the synchronizer ring against the cone and measure the clearance between the synchronizer ring and gear cone. Install a new synchronizer ring if the measurement is not within specification. Refer to the following chart for correct synchronizer ring clearance:
GEAR SPECIFICATION CHART

Gear mm Inch
3rd 0.9-1.45 0.035-0.057
4th 0.9-1.45 0.035-0.057
5th 0.95-1.4 0.037-0.055
Fig 10: Measuring Clearance Between Synchronizer Ring And Gear Cone
G06098243Courtesy of FORD MOTOR CO.
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