Input Shaft: Service and Repair

DISASSEMBLY





1. Remove the bearing using Bearing Pulling Attachment.

CAUTION: The bearing is damaged when it is pressed off using the Bearing Pulling Attachment and cannot be re-used.





2. Remove fifth gear.
1 Remove the snap-ring.
2 Remove fifth gear.





3. Remove the fourth gear.
1 Remove the fourth gear.
2 Remove the bearing.
3 Remove the synchronizer ring.





4. Remove the third/fourth gear synchronizer assembly.
1 Remove the snap-ring.
2 Remove the synchronizer assembly.





5. Remove the bearing using the Bearing Pulling Attachment.

CAUTION: The bearing is damaged when it is pressed off using the separating tool and cannot be re-used.

ASSEMBLY
1. Carefully clean and check all parts and lubricate them with Motorcraft MERCON Multi-purpose Automatic Transmission Fluid XT-2-QDX or equivalent meeting MERCON specification. MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4.





2. Install the bearing.
- Install the bearing using a suitable driver.

CAUTION: Immerse the double synchronizer units in a bath of Motorcraft MERCON Multi-purpose Automatic Transmission Fluid XT-2-QDX or equivalent meeting MERCON specification prior to installation.





3. Installation position of the synchronizer assembly.

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





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

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





5. Install fourth gear.
1 Install the synchronizer ring.
2 Install the bearing.
3 Install fourth gear.





6. Install fifth gear.
- Install fifth gear using a suitable driver.
- Install a new snap-ring.





7. Install the bearing.
- Install the bearing using a suitable driver.