Disassembly And Assembly Of Subassemblies: Mainshaft: Disassembly

WARNING: This page is about a different car, the 2008 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.

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	mm	Inch
1st	0.20-0.30	0.0078-0.0118
2nd	0.06-0.16	0.0024-0.0063

Fig 1: Checking End Play

Courtesy of FORD MOTOR CO.

Remove and discard the snap ring.
Remove the C-ring holder.
Remove the mainshaft C-ring.
Using the special tool, remove the mainshaft rear bearing.

Fig 2: Removing Mainshaft Rear Bearing

Courtesy of FORD MOTOR CO.

Remove and discard the snap ring.
Using the special tool, remove the 5th main gear and the 4th main gear together.
- Discard both gears.

Fig 3: Removing 5th Main Gear & 4th Main Gear

Courtesy of FORD MOTOR CO.

Remove the 4th gear main adjusting shim.
Remove the 3rd/4th gear shaft spacer.
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 Mainshaft Components

Courtesy of FORD MOTOR CO.

Inspect all mainshaft parts for damage, peeling, dents, uneven wear or bending. Install new parts as necessary.

Fig 5: Inspecting Mainshaft Parts

Courtesy of FORD MOTOR CO.

Inspect the synchronizer rings for damage. Install new parts as necessary.

Fig 6: Inspecting Synchronizer Rings

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.

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.

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

Fig 7: Checking 1st Gear Double Cone Synchronizer Clearances With Specifications

Courtesy of FORD MOTOR CO.

NOTE: If the difference in measurements is greater than 0.2 mm (0.078 in), install new parts.

Using the special tool, 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.

Fig 8: Checking Clearances

Courtesy of FORD MOTOR CO.

NOTE: If the difference in measurements is greater than 0.2 mm (0.078 in), install new parts.

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.

Fig 9: Checking Clearances Between Outer Synchronizer Ring & Synchronizer Cone

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 new as a set.

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 (0.01 in), install new parts.

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 10: Checking 2nd Gear Triple Cone Synchronizer Clearances With Specification

Courtesy of FORD MOTOR CO.

NOTE: If the difference in measurements is greater than 0.17 mm (0.007 in) install new parts.

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 11: Checking Clearances With Specification

Courtesy of FORD MOTOR CO.

NOTE: If the difference in measurements is greater than 0.3 mm (0.01 in), install new parts.

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: Checking 2nd Gear Triple Cone Synchronizer Clearances With Specification

Courtesy of FORD MOTOR CO.