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HOMESERVICE MANUALSFORD2005TAURUS SEL, 4D SEDANREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 918 (MANUAL TRANSMISSION)DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIESMAINSHAFTDISASSEMBLY
2005 Ford Taurus SEL, 4D Sedan

Disassembly And Assembly Of Subassemblies: Mainshaft: Disassembly

2005 Ford Taurus SEL, 4D SedanSECTION Disassembly
WARNING: This page is about a different car, the 2007 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
  1. Prior to disassembly of the mainshaft, measure and record the end play for 1st and 2nd gears. Refer to the following chart for standard values:
    Gear mm Inch
    1st 0.20-0.30 0.0078-0.0118
    2nd 0.06-0.16 0.0024-0.0063
    2. Fig 1: Checking End Play
    GF0025372Courtesy of FORD MOTOR CO.
  2. Remove and discard the snap ring.
  3. Remove the C-ring holder.
  4. Remove the mainshaft C-ring.
  5. Using the special tool, remove the mainshaft rear bearing.
    6. Fig 2: Removing Mainshaft Rear Bearing
    GF0025373Courtesy of FORD MOTOR CO.
  6. Remove and discard the snap ring.
  7. Using the special tool, remove the 5th main gear and the 4th main gear together.
    • Discard both gears.
    8. Fig 3: Removing 5th Main Gear & 4th Main Gear
    GF0025374Courtesy of FORD MOTOR CO.
  8. Remove the 4th gear main adjusting shim.
  9. Remove the 3rd/4th gear shaft spacer.
  10. Remove the 3rd main gear, 2nd main gear, 2nd gear needle bearing, 2nd gear bushing, 1st and 2nd gear synchronizer assembly, 1st and 2nd gear synchronizer rings, 1st main gear, reverse main gear, 1st gear needle bearing and 1st gear bushing together.
    • Discard the 3rd main gear, the reverse main gear, and the 1st and 2nd gear synchronizer assembly.
    11. Fig 4: Removing Mainshaft Components
    GF0025375Courtesy of FORD MOTOR CO.
  11. Inspect all mainshaft parts for damage, peeling, dents, uneven wear or bending. Install new parts as necessary.
    12. Fig 5: Inspecting Mainshaft Parts
    GF0025376Courtesy of FORD MOTOR CO.
  12. Inspect the synchronizer rings for damage. Install new parts as necessary.
    13. Fig 6: Inspecting Synchronizer Rings
    GF0025359Courtesy of FORD MOTOR CO.
RENDER: 1.0x

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Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.