LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Ford >> 2006 >> Focus ZX3 S >> 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 will be damaged when it is removed from the shaft. Do not reuse the bearing.
    Fig 1: Removing Roller Bearing
    G04653414Courtesy 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 will be damaged when it is removed from the shaft. Do not reuse the bearing.
    Fig 2: Removing Roller Bearing
    G04653415Courtesy of FORD MOTOR CO.
  2. Reposition the input shaft with 5th gear end facing upward. Using a suitable press and the special tool, remove the roller bearing.
  3. Using a press and the special tool, remove the snap ring and 5th gear.
  4. Remove the 4th gear.
    1. Remove the 4th gear.
    2. Remove the 4th gear needle bearing.
    3. Remove the synchronizer ring.
    • Check all components for wear or damage. Install new components as necessary.
      Fig 3: Removing Snap Ring And 5th Gear
      G04653416Courtesy of FORD MOTOR CO.
  5. Remove the 3rd/4th gear synchronizer assembly.
    1. Remove and discard the snap ring.
    2. Remove the 3rd/4th 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: Identifying 3rd/4th Gear Synchronizer Assembly And Snap Ring
        G04653417Courtesy of FORD MOTOR CO.
  6. Disassemble the 3rd/4th 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: Locating Detent Balls Spring-Loaded
      G04653418Courtesy of FORD MOTOR CO.
  7. Inspect the 3rd/4th 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, 3rd gear and the 3rd needle gear bearing.
    • Inspect the synchronizer ring, 3rd gear and the needle bearing for wear or damage. Install new components as necessary.
      Fig 6: Locating Synchronizer Ring, 3rd Gear And 3rd Gear Needle Bearing
      G04653419Courtesy of FORD MOTOR CO.
scientia non olet · About LEMON Manuals