Input Shaft: Disassembly

Prior to disassembly of the input shaft, measure and record the end play for the 3rd, 4th, and 5th gears. Refer to the following STANDARD VALUES FOR 3RD, 4TH, & 5TH GEAR END PLAY for standard values:

STANDARD VALUES FOR 3RD, 4TH, & 5TH GEAR END PLAY

Gear	mm	in
3RD	0.18 - 0.31	0.007 - 0.012
4TH	0.20 - 0.30	0.0078 - 0.0118
5TH	0.06 - 0.16	0.0023 - 0.0062

Fig 1: Measuring And Record End Play For 3rd, 4th, and 5th Gears

Courtesy of FORD MOTOR CO.

Remove the oil channel.
Using the special tool, remove the input shaft rear bearing.

Fig 2: Removing Input Shaft Rear Bearing
Courtesy of FORD MOTOR CO.

NOTE: The snap ring is not reusable.

Fig 3: Removing And Discard Snap Ring

Courtesy of FORD MOTOR CO.

Remove and discard the snap ring.
Using the special tool, remove the input shaft spacer and the 5th gear stopper together.

Fig 4: Removing Input Shaft Spacer And 5th Gear Stopper Together
Courtesy of FORD MOTOR CO.
Using the special tools, remove the 5th gear synchronizer assembly, the 5th gear synchronizer ring, and the 5th input gear together.
- Discard the 5th gear synchronizer ring and assembly.
  
  Fig 5: Discarding 5th Gear Synchronizer Ring And Assembly
  Courtesy of FORD MOTOR CO.
Remove the 5th gear needle bearing.
Using the special tools, remove the 5th gear bushing, thrust washer, 4th input gear, 4th gear needle bearing, 4th gear bushing, 4th gear synchronizer ring, 3rd and 4th gear synchronizer assembly, 3rd gear synchronizer ring, and 3rd input gear together.
- Discard the 5th gear bushing.
- Discard the 3rd and 4th gear synchronizer assembly.
  
  Fig 6: Discarding 3rd And 4th Gear Synchronizer Assembly
  Courtesy of FORD MOTOR CO.
Remove the 3rd gear needle bearing.
Using the special tool, remove the input shaft front bearing.

Fig 7: Removing Input Shaft Front Bearing
Courtesy of FORD MOTOR CO.
Inspect all input shaft parts for damage, peeling, dents, uneven wear or bending. Install new parts as necessary.

Fig 8: Inspecting All Input Shaft Parts For Damage
Courtesy of FORD MOTOR CO.
Inspect the synchronizer rings for damage. Install new parts as necessary.

Fig 9: Inspecting Synchronizer Rings For Damage
Courtesy of FORD MOTOR CO.

NOTE: Limit value: 0.7 mm (0.02 in).

Fig 10: Measuring Clearance Between Synchronizer Ring And Gear Cone

Courtesy of FORD MOTOR CO.

Press the synchronizer ring against the cone and measure the clearance between the synchronizer ring and gear cone. Install a new synchronizer ring if the measurement is not within specification. Refer to SYNCHRONIZER RING-TO-GEAR CONE CLEARANCE SPECIFICATIONS chart for correct synchronizer ring clearance:

SYNCHRONIZER RING-TO-GEAR CONE CLEARANCE SPECIFICATIONS

Gear	mm	in
3RD	0.9 - 1.45	0.035 - 0.057
4TH	0.9 - 1.45	0.035 - 0.057
5TH	0.95 - 1.4	0.037 - 0.055