Input Shaft: Disassembly

WARNING: This page is about a different car, the 2006 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.

Prior to disassembly of the input shaft, measure and record the end play for the 3rd, 4th and 5th gears. Refer to the following chart for standard values:

STANDARD VALUES SPECIFICATIONS CHART

Gear	mm	Inch
3rd	0.18-0.31	0.007-0.0122
4th	0.20-0.30	0.0078-0.0118
5th	0.06-0.16	0.0024-0.0063

Fig 1: Measuring End Play

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 Using Special Tool
Courtesy of FORD MOTOR CO.

NOTE: The snap ring is not reusable.

Fig 3: Locating 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 Using Special Tool
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: Removing 5th Gear Synchronizer, Synchronizer Ring And 5th Input Gear
  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: Identifying Special Tool
  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 Using Special Tool
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 Input Shaft Parts
Courtesy of FORD MOTOR CO.
Inspect the synchronizer rings for damage. Install new parts as necessary.

Fig 9: Inspecting Synchronizer Rings
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 the following chart for correct synchronizer ring clearance:

SYNCHRONIZER RING CLEARANCE SPECIFICATIONS CHART

Gear	mm	Inch
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