LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Ford >> 2005 >> Focus ZXW SES, Standard >> Repair and Diagnosis >> Transmission >> Manual Trans >> Manual Transmission >> Disassembly And Assembly Of Subassemblies >> Input Shaft >> Disassembly
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Input Shaft: Disassembly

CAUTION: The inner synchronizer ring and the synchronizer cone must be handled very carefully.
NOTE: If there any new installation of bearings, shafts or the transaxle housings is necessary, the transaxle must be shimmed.
    CAUTION: The roller bearing is damaged when it is pressed off using the special tool and cannot be reused.
    Fig 1: Removing Roller Bearing
    G04517328Courtesy of FORD MOTOR CO.
  1. Position the input shaft on the press with the input shaft splines facing upward. Using the special tool, remove and discard the roller bearing.
    2. CAUTION: The roller bearing is damaged when it is pressed off using the special tool and cannot be reused.
    Fig 2: Removing Roller Bearing
    G04517329Courtesy of FORD MOTOR CO.
  2. Reposition the input shaft with fifth gear end facing upward. Using a suitable press and the special tool, remove the roller bearing.
  3. Using a suitable press and the special tool, remove the snap ring and fifth gear.
  4. Remove the fourth gear.
    1. Remove the fourth gear.
    2. Remove the fourth gear needle bearing.
    3. Remove the synchronizer ring.
      • Check all components for wear or damage. Install new components as necessary.
        Fig 3: Removing Fourth Gear, Fourth Gear Needle Bearing And Synchronizer Ring
        G04517330Courtesy of FORD MOTOR CO.
  5. Remove the third/fourth gear synchronizer assembly.
    1. Remove and discard the snap ring.
    2. Remove the third/fourth gear synchronizer assembly
      • Check the synchronizer for wear or damage. Install a new synchronizer as necessary.
      • Inspect the gear for wear or damage. Install a new gear, as necessary.
        Fig 4: Removing Third/Fourth Gear Synchronizer Assembly
        G04517331Courtesy of FORD MOTOR CO.
  6. Disassemble the third/fourth gear synchronizer assembly. Remove the selector ring from the synchronizer hub. Remove the compression springs, the blocker bars and the detent balls.
    • Take care when pulling the selector ring off the gear synchronizer hub. The detent balls are spring-loaded.
      Fig 5: Pulling Selector Ring Off Gear Synchronizer Hub
      G04517332Courtesy of FORD MOTOR CO.
  7. Inspect the third/fourth synchronizer.
    • Check for worn, nicked or broken teeth. Install a new synchronizer as necessary.
    • Check keys for wear or distortion. Install a new synchronizer as necessary.
    • Check springs for distortion. Install a new synchronizer as necessary.
  8. Remove the synchronizer ring, third gear and the third needle gear bearing.
    • Inspect the synchronizer ring, third gear, and the needle bearing for wear or damage. Install new components as necessary.
      Fig 6: Inspecting Synchronizer Ring, Third Gear, And Needle Bearing For Wear Or Damage
      G04517333Courtesy of FORD MOTOR CO.
scientia non olet · About LEMON Manuals