Caution: See TSB 06-14-4

Idler Gear

1. CAUTION: Use protective vise plates to prevent damage to the special tool.

Use Torque Adapter to secure the idler gear shaft and remove the idler gear shaft nut.

1. Secure the idler gear shaft in a vise with Torque Adapter.
2. Remove the idler gear shaft nut.

2. Remove the (A) idler gear bearing and the (B) spacer.

3. Separate the (A) idler gear from the (B) idler gear shaft, then remove the remaining (C) idler gear bearing.

4. CAUTION: Use a protective material to prevent damage to the idler gear.

Remove the bearing cup.

1. Secure the idler gear in a vise and position Impact Slide Hammer with Bearing Cup Puller.
2. Remove the bearing cup.

5. Use Step Plate Adapter to press out the other bearing cup from the idler gear.

Assembly

1. Clean the components with a suitable solvent and use compressed air to dry all parts. Perform the following before assembly:

• Inspect idler gear for damaged or excessively worn teeth.
• Inspect the idler gear shaft for damage or wear.

2. Use Pinion Bearing Cup Replacer to press the new bearing cups into the idler gear.

3. Install a new (A) idler gear bearing onto the idler gear shaft, then install the (B) idler gear, (C) spacer, and the other new (D) idler gear bearing.

4. CAUTION: Use protective vise plates to prevent damage to the special tool.

Use Torque Adapter to secure the idler gear shaft in the vise.

5. Use (A) Mainshaft Locknut Wrench along with a (B) 1-5/8 inch socket and install the idler gear shaft nut.

6. Apply Motorcraft MERCON V Multi-Purpose Automatic Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON V to a new idler gear shaft seal and install it on the idler gear shaft. MERCON (R) Automatic Transmission Fluid is being replaced by MERCON (R) V as a service fluid, as per TSB 06-14-4.

• Idler gear shaft seal inner diameter: 40.5 mm (1.594 inch) .

7. CAUTION: Use protective vise plates to prevent damage to the idler gear.

NOTE: Take several measurements and calculate the average value.

Measure the idler gear shaft preload.

• Turn the idler gear and Torque Adapter over and secure the idler gear in a vise. Measure the preload when the idler gear shaft begins to rotate.

8. NOTE: The preload can be reduced by increasing the thickness of the spacer (adjusting shims).

If the specified preload cannot be obtained within the specified idler gear shaft nut torque, adjust it by selecting the proper spacer from the table below.