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Input Shaft: Assembly

    NOTE: Do not oil taper roller bearings which are to be used again. New taper roller bearings can be installed without any treatment.
  1. Carefully clean and check all sliding parts and lubricate them with Mercon® Multi-Purpose Automatic Transmission Fluid XT-2-QDX meeting Mercon® specification plus 2% Friction Modifier C8AZ-19B546-A meeting Ford specification EST-M2C118-A before installation.
    2. CAUTION: Immerse the double synchronizer units in a bath of Merkur manual transmission fluid before installation.
  2. Press the taper roller bearing on at the clutch side.
    • Press the taper roller bearing on using a suitable length of tube.
      Fig 1: Pressing Taper Roller Bearing On At Clutch Side
      G03419683Courtesy of FORD MOTOR CO.
    3. NOTE: See step:
  3. Install the third gear wheel.
    1. Needle roller bearing
    2. Third gear wheel
    3. Inner synchronizer ring
    4. Synchronizer cone
    5. Outer synchronizer ring
      Fig 2: Installing Third Gear Wheel
      G03419684Courtesy of FORD MOTOR CO.
    4. NOTE: Install the synchronizer hub with the large collar facing outwards and the annular groove facing the small collar.
    Fig 3: Identifying Synchronizer Assembly Installation Position
    G03419685Courtesy of FORD MOTOR CO.
  4. Installation position of the synchronizer assembly.
    5. NOTE: Install the synchronizer hub with the large collar facing outwards.
  5. Install the complete third/fourth gear synchronizer assembly.
    1. Synchronizer assembly.
    2. Install a new snap ring.
      Fig 4: Installing Third/Fourth Gear Synchronizer Assembly
      G03419686Courtesy of FORD MOTOR CO.
  6. Install the fourth gear wheel.
    1. Synchronizer ring.
    2. Needle roller bearing.
    3. Fourth gear wheel.
      Fig 5: Installing Fourth Gear Wheel
      G03419687Courtesy of FORD MOTOR CO.
  7. Press on the fifth gear wheel.
    • Press on the fifth gear wheel using a suitable length of tube.
    • Install a new snap ring.
      Fig 6: Pressing On Fifth Gear Wheel
      G03419688Courtesy of FORD MOTOR CO.
  8. Press on the taper roller bearing at the transaxle side.
    • Using a suitable length of tube, press on the taper roller bearing.
      Fig 7: Pressing On Taper Roller Bearing At Transaxle Side
      G03419689Courtesy of FORD MOTOR CO.
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