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Output Shaft: Assembly

    NOTE: Do not lubricate new roller bearings.
  1. Lubricate all transmission components with transmission fluid during reassembly.
    2. CAUTION: Handle the inner synchronizer ring and synchronizer cone very carefully.
  2. Install the following:
    1. The first gear needle bearing.
    2. First gear.
    3. The inner synchronizer ring.
    4. The synchronizer cone.
    5. The outer synchronizer ring.
      Fig 1: Installing Inner Synchronizer Ring And Outer Synchronizer Ring
      G04517357Courtesy of FORD MOTOR CO.
    3. NOTE: Observe the markings on the selector ring.
  3. Assemble the synchronizer hub assembly.
    1. Install the compression springs.
    2. Install the keys and the detent balls in the gear synchronizer hub against the force of the spring.
    3. Align the selector ring with the hub and push it on.
      Fig 2: Installing Keys And Detent Balls In Gear Synchronizer Hub
      G04517358Courtesy of FORD MOTOR CO.
    4. NOTE: Install the synchronizer hub assembly with the larger collar facing toward second gear.
    Fig 3: Installing First/Second Gear Synchronizer Hub Assembly
    G04517359Courtesy of FORD MOTOR CO.
  4. Install the first/second gear synchronizer hub assembly, then install a new snap ring.
  5. Install the following:
    1. The second gear needle bearing
    2. The outer synchronizer ring.
    3. The synchronizer cone.
    4. The inner synchronizer ring.
    5. Second gear.
      Fig 4: Installing Synchronizer Cone, Inner Synchronizer Ring And Second Gear
      G04517360Courtesy of FORD MOTOR CO.
  6. Using a suitable press and the special tool, install third gear.
    Fig 5: Installing Third Gear
    G04517361Courtesy of FORD MOTOR CO.
  7. Using a suitable press and the special tool, install fourth gear. Install a new snap ring.
    Fig 6: Installing Fourth Gear
    G04517362Courtesy of FORD MOTOR CO.
  8. Install the fifth gear needle bearing, fifth gear and the synchronizer ring.
    Fig 7: Installing Fifth Gear Needle Bearing, Fifth Gear And Synchronizer Ring
    G04517363Courtesy of FORD MOTOR CO.
    9. NOTE: Install the synchronizer hub assembly with the small collar and the ring groove facing outward.
    Fig 8: Installing Fifth/Reverse Gear Synchronizer Assembly
    G04517364Courtesy of FORD MOTOR CO.
  9. Install the fifth/reverse gear synchronizer assembly. Install a new snap ring.
  10. Install the synchronizer ring, the reverse gear needle bearing and the reverse gear.
    Fig 9: Installing Synchronizer Ring, Reverse Gear Needle Bearing And Reverse Gear
    G04517365Courtesy of FORD MOTOR CO.
  11. Using a suitable press, install a new output shaft bearing.
    Fig 10: Installing Output Shaft Bearing
    G04517366Courtesy of FORD MOTOR CO.
  12. Using a suitable press, install a new output shaft bearing.
    Fig 11: Installing Output Shaft Bearing
    G04517367Courtesy of FORD MOTOR CO.
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