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HOMESERVICE MANUALSFORD1999WINDSTAR BASE, VAN CARGO, 3.8 4REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1856 (MANUAL TRANSAXLE)DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES5TH/6TH GEARNOTES
1999 Ford Windstar Base, Van Cargo, 3.8 4

5th/6th Gear: Notes

1999 Ford Windstar Base, Van Cargo, 3.8 4SECTION Notes
WARNING: This page is about a different car, the 2010 Mercury Milan and 2010 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
  1. Inspect the 5th and 6th gear synchronizer cones, gear teeth and rings for wear or damage. Replace as necessary.
  2. Using a feeler gauge, while applying pressure and rotating the synchronizer ring, measure the clearance between the 5th gear synchronizer ring and the flank surface of the gear. The measurement should be the same around the entire circumference. Replace the synchronizer ring if less than the minimum specification.
    NOTE: Set the synchronizer ring squarely on the gear and measure around the circumference.
    5TH GEAR SYNCHRONIZER RING CLEARANCE SPECIFICATION TABLE

    Standard Minimum
    1.50 mm (0.059 in) 0.80 mm (0.031 in)
    Fig 1: Measuring Clearance Between 5th Gear Synchronizer Ring & Flank Surface Of Gear
    G06275944Courtesy of FORD MOTOR CO.
  3. Using a feeler gauge, while applying pressure and rotating the synchronizer ring, measure the clearance between the 6th gear synchronizer ring and the flank surface of the gear. The measurement should be the same around the entire circumference. Replace the synchronizer ring if less than the minimum specification.
    NOTE: Set the synchronizer ring squarely on the gear and measure around the circumference.
    6TH GEAR SYNCHRONIZER RING CLEARANCE SPECIFICATION TABLE

    Standard Minimum
    1.50 mm (0.059 in) 0.80 mm (0.031 in)
    Fig 2: Measuring Clearance Between 6th Gear Synchronizer Ring & Flank Surface Of Gear
    G06275945Courtesy of FORD MOTOR CO.
  4. Measure the clearance between the clutch hub sleeve and the shift fork. Replace if it exceeds the maximum specification.
    • Inspect the clutch hub sleeve and clutch hub operation. Replace if there is a malfunction.
    5TH/6TH GEAR CLUTCH HUB SLEEVE AND SHIFT FORK CLEARANCE SPECIFICATION TABLE

    Standard Maximum
    0.10-0.36 mm (0.004-0.014 in) 0.86 mm (0.033 in)
    Fig 3: Measuring Clearance Between Clutch Hub Sleeve & Shift Fork
    G06275946Courtesy of FORD MOTOR CO.
  5. Using a telescoping gauge, measure the ID of the 5th gear. Using a micrometer, measure the OD of the gear sleeve.
    Fig 4: Measuring OD
    G06275947Courtesy of FORD MOTOR CO.
  6. Measure the telescoping gauge to determine if the gear to the gear sleeve clearances are within specifications. If not within specifications, replace as needed.
    Fig 5: Measuring Telescoping Gauge With Micrometer
    G06064088Courtesy of FORD MOTOR CO.
  7. Using a telescoping gauge, measure the ID of the 6th gear. Using a micrometer, measure the OD of the gear sleeve.
    Fig 6: Measuring ID Of 6th Gear
    G06275949Courtesy of FORD MOTOR CO.
  8. Measure the telescoping gauge to determine if the gear to the gear sleeve clearances are within specifications. If not within specifications, replace as needed.
RENDER: 1.0x

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