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Mainshaft - Vehicles Built From: 12-2004 > < Transaxle - Vehicles Built From: 12-2003

Maverick 2005 (08.2004-)

Manual Transmission/Transaxle - Input Shaft—Vehicles Built From: 12/2004 Maverick 2005 (08/2004-)
Disassembly and Assembly of Subassemblies

Special Tool(s)

Installer, Spindle/Axle Shaft

205-199 or equivalent

Puller, Bearing

205-D064 or equivalent

Input Bearing Installer

308-582 or equivalent

 
Item
Part Number
Description
1
7L276
Oil channel
2
7A453
Input shaft rear bearing
3
4097
Snap ring
4
7N112
Input shaft spacer
5
7L049
5th gear stopper
6
7L052
5th gear synchronizer assembly
7
7107
5th gear synchronizer ring
8
7144
5th input gear
9
7K275
5th gear needle bearing
10
7N090
5th gear bushing
11
7G103
Thrust washer
12
7112
4th input gear
13
7065
4th gear needle bearing
14
7N090
4th gear bushing
15
7107
4th gear synchronizer ring
16
7K160
3rd and 4th gears synchronizer assembly
17
7107
3rd gear synchronizer ring
18
7N315
3rd input gear
19
7065
3rd gear needle bearing
20
7017
Input shaft
21
7G429
Input shaft front bearing

Disassembly
  1. 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:
    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
  1. Remove the oil channel.

  1. Using the special tool, remove the input shaft rear bearing.

  1. NOTE:
    NOTE:The snap ring is not reusable.
    Remove and discard the snap ring.

  1. Using the special tool, remove the input shaft spacer and the 5th gear stopper together.

  1. 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.
  1. Remove the 5th gear needle bearing.

  1. 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.
  1. Remove the 3rd gear needle bearing.

  1. Using the special tool, remove the input shaft front bearing.

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

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

  1. NOTE:
    NOTE: Limit value: 0.7 mm (0.02 in).
    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:
    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

Assembly
  1. Using the special tools, install the input shaft front bearing.
  1. Install the 3rd gear needle bearing.
  1. Install the 3rd input gear.
  1. Install the 3rd gear synchronizer ring.

  1. CAUTION:
    CAUTION:Make sure the synchronizer side with 3 notches is facing the 3rd input gear and the synchronizer side with 4 notches is facing the 4th gear.
    Install a new 3rd and 4th gear synchronizer assembly.
  1. Install the 4th gear synchronizer ring.

  1. Using the special tools, install the 4th gear bushing.
  1. Install the 4th gear needle bearing.
  1. Install the 4th input gear.

  1. CAUTION:
    CAUTION: Only one thrust washer can be selected.
    Select the correct thickness thrust washer.
    • Measure the distance as shown.
    • If the measurement is not within 154.7-154.8 mm (6.090-6.094 in), select the correct thickness of shim from the following chart:
      • mm Inch
      3.84 0.151
      3.90 0.153
      3.96 0.155
      4.02 0.158
      4.08 0.16
      4.14 0.162

  1. Using the special tools, install the thrust washer.

  1. Using the special tools, install a new 5th gear bushing.
  1. Install the 5th gear needle bearing.
  1. Install the 5th input gear.
  1. Install a new 5th gear synchronizer ring.

  1. CAUTION:
    CAUTION: Make sure the synchronizer side with the 3 notches is facing the 4th input gear.
    Install a new 5th gear synchronizer assembly.

  1. Using the special tools, install the 5th gear stopper and input shaft bearing spacer together.
  1. Install the input shaft spacer.

  1. Install new snap ring. Measure the gap between the snap ring groove and the snap ring. The end play should be between 0-0.1 mm (0-0.0039 in). Refer to the following chart for the correct snap ring thickness:
    mm Inch
    1.71 0.067
    1.76 0.069
    1.81 0.071
    1.86 0.073
    1.91 0.075
    1.96 0.077
    2.01 0.079
    2.06 0.081
    2.11 0.083
    2.16 0.085
    2.21 0.087
    2.26 0.088

  1. Using the special tools, install the input shaft rear bearing.
  1. Install the oil channel.

Mainshaft - Vehicles Built From: 12-2004 > < Transaxle - Vehicles Built From: 12-2003