Input Shaft: Disassembly

CAUTION: The inner synchronizer ring and the synchronizer cone must be handled very carefully.

NOTE: The design and assembly procedure for the third gear single synchronizer are the same as for fourth gear. The following steps are for a double synchronizer. Refer to the table in SPECIFICATIONS if synchronizer parts have to be newly installed.

NOTE: If there any new installation of bearings, shafts or the transaxle housings is necessary, the transaxle must be shimmed.

NOTE: See "DESCRIPTION AND OPERATION " for a general view of the input shaft.

CAUTION: The taper roller bearing is damaged when it is pressed off using the special tool and cannot be reused.

Fig 1: Pressing Taper Roller Bearing (On Clutch Side) Off Driveshaft

Courtesy of FORD MOTOR CO.

Using the special tool, press the taper roller bearing on the clutch side off the driveshaft.

CAUTION: The taper roller bearing is damaged when it is pressed off using the special tool and cannot be reused.

Fig 2: Pressing Taper Roller Bearing (Transaxle Side) Off Driveshaft

Courtesy of FORD MOTOR CO.

Using the special tool, press the taper roller bearing on the transaxle side off the driveshaft.

NOTE: See also Step for alternative removal procedure of the fifth gear wheel.

Press off the fifth gear wheel with the taper roller bearing.
1. Slide the snap ring out of the annular groove until it sits below the taper roller bearing.
2. Using the Gear removal support plate, press off the fifth gear wheel together with the snap ring and taper roller bearing.
  
  Fig 3: Removing Fifth Gear Wheel With Taper Roller Bearing (1 Of 2)
  Courtesy of FORD MOTOR CO.

CAUTION: Parts can be damaged when it is pressed off using the special tool or an equivalent tool.

Press off the fifth gear wheel with the taper roller bearing.
1. Slide the snap ring out of the annular groove until it sits below the taper roller bearing.
2. Using the special tool, press off the fifth gear wheel together with the snap ring and taper roller bearing.
  
  Fig 4: Removing Fifth Gear Wheel With Taper Roller Bearing (2 Of 2)
  Courtesy of FORD MOTOR CO.
Remove the fourth gear wheel.
1. Fourth gear wheel.
2. Needle roller bearing.
3. Synchronizer ring.
  
  Fig 5: Removing Fourth Gear Wheel
  Courtesy of FORD MOTOR CO.
Remove the third/fourth gear synchronizer assembly.
1. Snap ring.
2. Synchronizer assembly.
  
  Fig 6: Removing Third/Fourth Gear Synchronizer Assembly
  Courtesy of FORD MOTOR CO.
Remove the third gear wheel.
1. Outer synchronizer ring
2. Synchronizer cone
3. Inner synchronizer ring
4. Third gear wheel
5. Needle roller bearing
  
  Fig 7: Removing Third Gear Wheel
  Courtesy of FORD MOTOR CO.