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Input Shaft: Assembly

WARNING: This page is about a different car, the 2008 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
  1. Using the special tools, install the input shaft front bearing.
    2. Fig 1: Installing Input Shaft Front Bearing
    GF0025361Courtesy 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.
  5. Install a new 3rd and 4th gear synchronizer assembly.
    6. Fig 2: Identifying Synchronizer Sides
    GF0025362Courtesy of FORD MOTOR CO.
  6. Install the 4th gear synchronizer ring.
  7. Using the special tools, install the 4th gear bushing.
    8. Fig 3: Installing 4th Gear Bushing
    GF0025363Courtesy 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.
  10. Select the correct thickness thrust washer.
    • Measure the distance as shown.
    • 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:
      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. Fig 4: Measuring Distance For Shim
    GF0025364Courtesy of FORD MOTOR CO.
  11. Using the special tools, install the thrust washer.
    12. Fig 5: Installing Thrust Washer
    GF0025365Courtesy of FORD MOTOR CO.
  12. Using the special tools, install a new 5th gear bushing.
    13. Fig 6: Installing 5th Gear Bushing
    GF0025366Courtesy 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.
  16. Install a new 5th gear synchronizer assembly.
    17. Fig 7: Identifying Synchronizer Side
    GF0025367Courtesy of FORD MOTOR CO.
  17. Using the special tools, install the 5th gear stopper and input shaft bearing spacer together.
    18. Fig 8: Installing 5th Gear Stopper & Input Shaft Bearing Spacer
    GF0025368Courtesy 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 (0-0.0039 in). Refer to the following chart for the correct snap ring thickness:
    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
    20. Fig 9: Checking Snap Ring Clearance
    GF0025369Courtesy of FORD MOTOR CO.
  20. Using the special tools, install the input shaft rear bearing.
    21. Fig 10: Installing Input Shaft Rear Bearing
    GF0025370Courtesy of FORD MOTOR CO.
  21. Install the oil channel.
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