Disassembly And Assembly Of Subassemblies: Mainshaft: Disassembly

1. Prior to disassembly of the mainshaft, measure and record the end play for 1st and 2nd gears. Refer to the following chart for standard values:
   GEAR SPECIFICATION CHART
   
   

   Gear	mm	Inch
   1st	0.20-0.30	0.007-0.011
   2nd	0.06-0.16	0.002-0.006

   Fig 1: Measuring End Play For 1st And 2nd Gears

   Courtesy of FORD MOTOR CO.
2. Remove and discard the snap ring.
3. Remove the C-ring holder.
4. Remove the mainshaft C-ring.
5. Using the Bearing Puller and a suitable press, remove the mainshaft rear bearing.
   Fig 2: Removing Mainshaft Rear Bearing Using Special Tool

   Courtesy of FORD MOTOR CO.
6. Remove and discard the snap ring.
7. Using the Bearing Puller and a suitable press, remove the 5th main gear and the 4th main gear together.
   • Discard both gears.
   Fig 3: Removing 5th Main Gear And 4th Main Gear Together Using Special Tool

   Courtesy of FORD MOTOR CO.
8. Remove the 4th gear main adjusting shim.
9. Remove the 3rd/4th gear shaft spacer.
10. Remove the 3rd main gear, 2nd main gear, 2nd gear needle bearing, 2nd gear bushing, 1st and 2nd gear synchronizer assembly, 1st and 2nd gear synchronizer rings, 1st main gear, reverse main gear, 1st gear needle bearing and 1st gear bushing together.
    • Discard the 3rd main gear, the reverse main gear, and the 1st and 2nd gear synchronizer assembly.
    Fig 4: Removing 4th Gear Main Adjusting Shim

    Courtesy of FORD MOTOR CO.
11. Inspect all mainshaft parts for damage, peeling, dents, uneven wear or bending. Install new parts as necessary.
    Fig 5: Inspecting Mainshaft Parts For Damage, Peeling And Dents

    Courtesy of FORD MOTOR CO.
12. Inspect the synchronizer rings for damage. Install new parts as necessary.
    Fig 6: Identifying Synchronizer Rings With Damage

    Courtesy of FORD MOTOR CO.
NOTE: The outer synchronizer ring, synchronizer cone and inner synchronizer ring have a set control clearance. If the measurement exceeds specification, install all 3 parts as a set.
Fig 7: Checking Clearances Of Double Cone Synchronizer For 1st Gear With Specifications
Courtesy of FORD MOTOR CO.
ITEM DESCRIPTION CHART



Item	Part Number	Description
1	7107	Inner ring
2	7C115	Synchronizer cone
3	7107	Outer ring

13. Check the clearances of the double cone synchronizer for 1st gear. If any of the clearances are beyond specification, install new parts as a set.
NOTE: If the difference in measurements is greater than 0.2 mm (0.007 in), install new parts.
Fig 8: Measuring Clearance Between Synchronizer Cone And Inner Synchronizer Ring Using Special Tools
Courtesy of FORD MOTOR CO.
14. Using the Dial Indicator Gauge with Holding Fixture and the Bearing Puller, measure the clearance at 2 or more points diagonally between the synchronizer cone and the inner synchronizer ring. Install new parts if not within specification.
NOTE: If the difference in measurements is greater than 0.2 mm (0.007 in), install new parts.
Fig 9: Measuring Clearance Between Outer Synchronizer Ring And Synchronizer Cone
Courtesy of FORD MOTOR CO.
15. Measure the clearance between the outer synchronizer ring and the synchronizer cone at 2 or more points diagonally opposite and calculate the mean value. Install new parts if not within specification.
NOTE: The outer synchronizer ring, synchronizer cone and inner synchronizer ring have a set control clearance. If the measurement exceeds specification, install all 3 parts new as a set.
16. Check the clearances of the triple cone synchronizer for 2nd gear. If any of the clearances are beyond specification, install new parts as a set.
NOTE: If the difference in measurements is greater than 0.3 mm (0.011 in), install new parts.
Fig 10: Checking Clearances Of Triple Cone Synchronizer For 2nd Gear With Specifications
Courtesy of FORD MOTOR CO.
17. Measure the clearance at 2 or more points diagonally opposite and calculate the mean. If the measurement is not within specification, install new parts.
NOTE: If the difference in measurements is greater than 0.17 mm (0.006 in) install new parts.
Fig 11: Measuring Synchronizer Clearance With Specifications
Courtesy of FORD MOTOR CO.
18. Measure the clearance at 2 or more points diagonally opposite and calculate the mean. If the measurement is not within specification, install new parts.
NOTE: If the difference in measurements is greater than 0.3 mm (0.011 in), install new parts.
19. Measure the clearance at 2 or more points diagonally opposite and calculate the mean. If the measurement is not within specification, install new parts.

Fig 12: Measuring Synchronizer Clearance With Specifications

Courtesy of FORD MOTOR CO.