Input Shaft

Input Shaft

Special Tools:

Special Tool(s)

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.





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

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





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

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





3. 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.





4. 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.





5. Remove the fourth gear wheel.
1 Fourth gear wheel.
2 Needle roller bearing.
3 Synchronizer ring.





6. Remove the third/fourth gear synchronizer assembly.
1 Snap ring.
2 Synchronizer assembly.





7. Remove the third gear wheel.
1 Outer synchronizer ring
2 Synchronizer cone
3 Inner synchronizer ring
4 Third gear wheel
5 Needle roller bearing

Assembly

1. NOTE: Do not oil taper roller bearings, which are to be used again. New taper roller bearings can be installed without any treatment. Carefully clean and check all sliding parts and lubricate them with MERCON Multipurpose Automatic Transmission Fluid XT-2-QDX meeting MERCON specification plus No Friction Modifier C8AZ-9B546-A meeting Ford specification EST-M2C118-A before installation. MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4.





2. CAUTION: Immerse the double synchronizer units in a bath of Merkur manual transmission fluid before installation.

Press the taper roller bearing on at the clutch side.
- Press the taper roller bearing on using a suitable length of tube.





3. NOTE: See step Install the third gear wheel.

1 Needle roller bearing
2 Third gear wheel
3 Inner synchronizer ring
4 Synchronizer cone 5 Outer synchronizer ring





4. NOTE: Install the synchronizer hub with the large collar facing outwards and the annular groove facing the small collar.

Installation position of the synchronizer assembly.





5. NOTE: Install the synchronizer hub with the large collar facing outwards.

Install the complete third/fourth gear synchronizer assembly.
1 Synchronizer assembly.
2 Install a new snap ring.





6. Install the fourth gear wheel.
1 Synchronizer ring.
2 Needle roller bearing.
3 Fourth gear wheel.





7. Press on the fifth gear wheel.
- Press on the fifth gear wheel using a suitable length of tube.
- Install a new snap ring.





8. Press on the taper roller bearing at the transaxle side. Using a suitable length of tube, press on the taper roller bearing.