Disassembly And Assembly Of Subassemblies: Mainshaft: Assembly

NOTE: Be careful with the orientation of the reverse main gear or damage to the component may occur.

Fig 1: Identifying Reverse Main Gear On Mainshaft

Courtesy of FORD MOTOR CO.

Position the reverse main gear on the mainshaft.
Using the Spindle/Axle Shaft Installer, press on a new reverse main gear.

Fig 2: Pressing Reverse Main Gear Using Special Tool
Courtesy of FORD MOTOR CO.
Install the 1st main gear.
Using the Bearing/Oil Seal Plate and the Sixth Gear Bushing Installer, press on the 1st main gear bushing.

Fig 3: Pressing 1st Main Gear Bushing Using Special Tools
Courtesy of FORD MOTOR CO.
Install the 1st gear needle bearing.
Install the 1st gear synchronizer ring.

NOTE: Make sure the synchronizer side with 3 notches is facing 1st gear and the synchronizer side with 4 notches is facing 2nd gear.

Fig 4: Identifying Gear Synchronizer Assembly

Courtesy of FORD MOTOR CO.

Position a new 1st and 2nd gear synchronizer assembly on the mainshaft.
Using the Spindle/Axle Shaft Installer and the Bearing Puller, press on the 1st and 2nd gear synchronizer assembly.

Fig 5: Pressing 1st And 2nd Gear Synchronizer Assembly Using Special Tools
Courtesy of FORD MOTOR CO.
Install the 2nd gear synchronizer ring.
Using the Bearing/Oil Seal Plate and the Second Gear Bushing Installer, press on the 2nd gear bushing.

Fig 6: Pressing 2nd Gear Bushing Using Special Tools
Courtesy of FORD MOTOR CO.
Install the 2nd gear needle bearing.
Install the 2nd main gear.

NOTE: Be careful with the orientation of the 3rd main gear.

Fig 7: Pressing 3rd Main Gear Using Special Tools

Courtesy of FORD MOTOR CO.

Using the Spindle/Axle Shaft Installer and the Bearing Puller, press on a new 3rd main gear.
Install the 3rd/4th main gear shaft spacer.

NOTE: Only one adjusting shim can be installed.

Fig 8: Measuring 4th Main Gear Adjusting Shim With Specifications

Courtesy of FORD MOTOR CO.

Measure the mainshaft components as indicated to select the appropriate 4th main gear adjusting shim. Refer to the following table for shim thicknesses and install the 4th main gear adjusting shim:

THICKNESS SPECIFICATION

mm	Inch
0.52	0.02
0.60	0.023
0.68	0.026
0.76	0.029
0.84	0.033
0.92	0.036
1.00	0.039
1.08	0.042

NOTE: Be careful with the orientation of the 4th main gear.

Fig 9: Pressing 4th Main Gear Using Special Tool

Courtesy of FORD MOTOR CO.

Using the Spindle/Axle Shaft Installer, press on a new 4th main gear.

NOTE: Be careful with the orientation of the 5th main gear.

Fig 10: Pressing 5th Main Gear Using Special Tool

Courtesy of FORD MOTOR CO.

Using the Spindle/Axle Shaft Installer, press on a new 5th main gear.

Measure the gap between the snap ring and the 5th main gear. The end play should be less than 0.1 mm (0.0039 in). Refer to the following chart to select the appropriate snap ring thickness and install a new snap ring:

THICKNESS SPECIFICATION

mm	Inch
1.85	0.072
1.90	0.074
1.95	0.076
2.00	0.078
2.05	0.08
2.10	0.082
2.15	0.084
2.20	0.086

Fig 11: Measuring Gap Between Snap Ring And 5th Main Gear

Courtesy of FORD MOTOR CO.

NOTE: Be careful with the orientation of the mainshaft rear bearing.

Fig 12: Pressing Mainshaft Rear Bearing Using Special Tool

Courtesy of FORD MOTOR CO.

Using the Spindle/Axle Shaft Installer, press on the mainshaft rear bearing.

Measure the gap between the mainshaft C-ring and the mainshaft rear bearing. Refer to the following chart to select the appropriate C-ring thickness and install the C-ring:

THICKNESS SPECIFICATION

mm	Inch
2.535	0.099
2.565	0.1
2.595	0.102
2.625	0.103
2.655	0.104
2.685	0.105
2.715	0.106
2.745	0.108
2.775	0.109
2.805	0.11
2.835	0.111
2.865	0.112
2.895	0.113
2.925	0.115
2.955	0.116
2.985	0.117
3.015	0.118
3.045	0.119
3.075	0.121

Fig 13: Measuring Gap Between Mainshaft C-Ring And Mainshaft Rear Bearing

Courtesy of FORD MOTOR CO.

Install the C-ring holder.
Install a new snap ring.