UNITIZED TRANSAXLE
Component Assembly
2000 FE290 Gasoline Vehicle Maintenance and Service Supplement Page 16-23
16
COMPONENT ASSEMBLY
Read DANGER and WARNING on page 16-1.
IDLER SHAFT ASSEMBLY
1. Press a new bearing (66) (Figure 16-42, Page 16-18) onto each end of the idler shaft (Figure 16-55,
Page 16-23). See following CAUTION.
INTERMEDIATE GEAR ASSEMBLY
1. If the gear (58) was removed from the shaft, install the key (57) into the slot and then position the gear on the
shaft with keyway properly aligned with key. Press gear into place on the key (Figure 16-42, Page 16-18).
2. Press the bearing (59) onto the end of the shaft next to the large gear that was installed in step one
(Figure 16-42, Page 16-18). See preceding CAUTION.
3. Press a new bearing (38) onto the other end of the shaft (Figure 16-42, Page 16-18).
SYNCHRONIZER GEAR ASSEMBLY
1. Press the synchronizer sleeve (47) onto the splines of the input shaft (51) (Figure 16-42, Page 16-18).
No particular orientation of the sleeve is necessary, but toward the short end of the shaft, the machined
circular face surrounding the ends of the internal splines in the sleeve must be flush with the machined
lip of the shaft at the ends of the shaft splines (Figure 16-56, Page 16-24).
2. Install the synchronizer springs (46) (Figure 16-42, Page 16-18) in the sleeve as shown (Figure 16-57,
Page 16-24).
• APPLY PRESSURE AGAINST THE INNER RACE OF THE BEARING ONLY. APPLYING
PRESSURE ANYWHERE ELSE WILL DAMAGE THE BEARING.
• MAKE SURE THE ENDS OF THE SPRINGS ARE POSITIONED BETWEEN THE SYNCHRONIZER
INSERT SLOTS (FIGURE 16-57, PAGE 16-24).
Figure 16-54 Synchro. Ring
Figure 16-55 Idler Shaft
CAUTION
NOTE
Synchro ring must be
replaced when (x)
distance is less than
.02 in (0.5 mm).
X
Press bearing
onto idler shaft.
Turn idler shaft
over and press
bearing on
other end.
B
A