Output Shaft: Assembly

WARNING: This page is about a different car, the 2005 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.

Lubricate all output shaft components with the recommended lubricant during reassembly.
Install the 2nd gear needle bearing.

Fig 1: Installing 2nd Gear Needle Bearing
Courtesy of FORD MOTOR CO.
Install 2nd gear.

Fig 2: Installing 2nd Gear
Courtesy of FORD MOTOR CO.
Install the inner and outer 2nd gear synchronizer blocking rings.
- Align the tabs on the outer blocking ring with the notches in the gear.
Fig 3: Installing Inner And Outer 2nd Gear Synchronizer Blocking Rings
Courtesy of FORD MOTOR CO.
Install the 2nd gear synchronizer blocking ring and the 1st/2nd gear synchronizer assembly.
- Align the tabs on the inner blocking ring with the spaces on the 2nd gear synchronizer blocking ring.
Fig 4: Installing 2nd Gear Synchronizer Blocking Ring And 1st/2nd Gear Synchronizer Assembly
Courtesy of FORD MOTOR CO.
Install the following components:
1. Install the 1st gear synchronizer blocking ring.
2. Install the outer synchronizer blocking ring.
3. Install the inner synchronizer blocking ring.
- Align the tabs on the inner blocking ring with the spaces on the 2nd gear synchronizer blocking ring.
Fig 5: Installing 1st Gear Synchronizer Blocking Ring, Outer Synchronizer Blocking Ring And Inner Synchronizer Blocking Ring
Courtesy of FORD MOTOR CO.
Install the 1st gear needle bearing.

Fig 6: Installing 1st Gear Needle Bearing
Courtesy of FORD MOTOR CO.
Install 1st gear and the sleeve.
- Align the tabs on the outer blocking ring with the notches in the gear.
Fig 7: Installing 1st Gear And Sleeve
Courtesy of FORD MOTOR CO.

CAUTION: Press the output shaft center bearing onto the shaft by the inner race only. Pressing on the outer race will damage the bearing.

Fig 8: Installing Output Shaft Bearing Using Special Tools

Courtesy of FORD MOTOR CO.

Using the special tools, install the output shaft bearing.
- Make sure the bearing is installed against 1st gear.

NOTE: Rotate the shaft so the output end is facing downward

Fig 9: Installing 3rd Gear Needle Bearing

Courtesy of FORD MOTOR CO.

Install the 3rd gear needle bearing.
Install 3rd gear.

Fig 10: Installing 3rd Gear
Courtesy of FORD MOTOR CO.
Install the inner and outer 3rd gear synchronizer blocking rings.
- Align the tabs on the outer blocking ring with the notches in the gear.
Fig 11: Installing Inner And Outer 3rd Gear Synchronizer Blocking Rings
Courtesy of FORD MOTOR CO.
Install the following components:
- 3rd gear synchronizer blocking ring
  - Align the tabs on the inner blocking ring with the spaces on the 3rd gear synchronizer blocking ring.
- 3rd/4th gear synchronizer assembly
- Spacer
- Thrust washer
Install the 4th gear synchronizer blocking ring and the snap ring.
- Inspect the blocking ring for wear or damage. Install a new blocking ring as necessary.
Fig 12: Installing 4th Gear Synchronizer Blocking Ring And Snap Ring
Courtesy of FORD MOTOR CO.
Using a feeler gauge, check the 3rd/4th synchronizer hub end play.
- If the clearance is not within specifications, select the correct snap ring.
- Available snap ring sizes:
  - 1.50 mm (0.05 in)
  - 1.55 mm (0.06 in)
  - 1.60 mm (0.06 in)
  - 1.65 mm (0.06 in)
  - 1.70 mm (0.06 in)
  - 1.75 mm (0.06 in)
  - 1.80 mm (0.07 in)
  - 1.85 mm (0.07 in)
  - 1.90 mm (0.07 in)
  - 1.95 mm (0.07 in)
Fig 13: Using Feeler Gauge To Check 3rd/4th Synchronizer Hub End Play
Courtesy of FORD MOTOR CO.
Install the input shaft needle bearing.