Disassembly And Assembly Of Subassemblies: Mainshaft: 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.

CAUTION: Be careful with the orientation of the reverse main gear.

Position the reverse main gear on the mainshaft.

Fig 1: Identifying Reverse Main Gear Orientation

Courtesy of FORD MOTOR CO.

Using the special tool, install a new reverse main gear.

Fig 2: Installing Reverse Main Gear

Courtesy of FORD MOTOR CO.

Install the 1st main gear.
Using the special tools, install the 1st main gear bushing.

Fig 3: Installing 1st Main Gear Bushing

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.

Position a new 1st and 2nd gear synchronizer assembly on the mainshaft.

Fig 4: Identifying Synchronizer Sides

Courtesy of FORD MOTOR CO.

Using the special tools, install the 1st and 2nd gear synchronizer assembly.

Fig 5: Installing 1st & 2nd Gear Synchronizer Assembly

Courtesy of FORD MOTOR CO.

Install the 2nd gear synchronizer ring.
Using the special tools, install the 2nd gear bushing.

Fig 6: Installing 2nd Gear Bushing

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.

Using the special tools, install a new 3rd main gear.

Fig 7: Installing 3rd Main Gear

Courtesy of FORD MOTOR CO.

Install the 3rd/4th main gear shaft spacer.

NOTE: Only one adjusting shim can be installed.

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:

mm	Inch
0.52	0.021
0.60	0.024
0.68	0.027
0.76	0.030
0.84	0.033
0.92	0.036
1.00	0.039
1.08	0.043

Fig 8: Measuring Mainshaft Components With Specification

Courtesy of FORD MOTOR CO.

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

Using the special tool, install a new 4th main gear.

Fig 9: Installing 4th Main Gear

Courtesy of FORD MOTOR CO.

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

Using the special tool, install a new 5th main gear.

Fig 10: Installing 5th Main Gear

Courtesy of FORD MOTOR CO.

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:

mm	Inch
1.85	0.073
1.90	0.075
1.95	0.077
2.00	0.079
2.05	0.081
2.10	0.083
2.15	0.085
2.20	0.087

Fig 11: Measuring Snap Ring & 5th Main Gear Clearance

Courtesy of FORD MOTOR CO.

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

Using the special tool, install the mainshaft rear bearing.

Fig 12: Installing Mainshaft Rear Bearing

Courtesy of FORD MOTOR CO.

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:

mm	Inch
2.535	0.0998
2.565	0.1010
2.595	0.1022
2.625	0.1033
2.655	0.1045
2.685	0.1057
2.715	0.1069
2.745	0.1081
2.775	0.1093
2.805	0.1104
2.835	0.1116
2.865	0.1128
2.895	0.1140
2.925	0.1152
2.955	0.1163
2.985	0.1175
3.015	0.1187
3.045	0.1199
3.075	0.1211

Fig 13: Measuring C Ring & Mainshaft Bearing Clearance

Courtesy of FORD MOTOR CO.

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