Output Shaft & Bearing: Assembly

WARNING: This page is about a different car, the 2002 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.

Using the special tool, check the output shaft runout.
- Check runout in several places along the output shaft. If runout exceeds specification, install a new output shaft.
Fig 1: Checking Output Shaft Runout
Courtesy of FORD MOTOR CO.
Identify the synchronizer blocking ring.
1. First gear synchronizer blocking ring (R1 model)
2. Third gear synchronizer blocking ring (R1 and R1 HD models)
3. First gear synchronizer blocking ring (R1 HD model)
4. Second and fourth gear synchronizer ring (R1 and R1 HD models)
Fig 2: Identifying Synchronizer Blocking Rings
Courtesy of FORD MOTOR CO.

Fig 3: Synchronizer Blocking Ring Specifications Chart
Courtesy of FORD MOTOR CO.
Inspect the synchronizer blocking rings for correct contact with the cone surface of first gear.

Fig 4: Inspecting Synchronizer Blocking Rings
Courtesy of FORD MOTOR CO.
Inspect the synchronizer blocking rings for wear on second gear.
- Vehicles equipped with 2.3L and 3.0L engines have dual cone blocking rings. Measure both blocking rings.
- If clearance is less than specification, install a new blocking ring or gear.
Fig 5: Inspecting Synchronizer Blocking Rings
Courtesy of FORD MOTOR CO.

Fig 6: Exploded View Of First & Second Gear Assembly
Courtesy of FORD MOTOR CO.
Assemble the first and second gear assembly as follows.
1. Install the second gear needle bearing.
2. Install the second gear.
3. Install the second synchronizer blocking ring.
  - Vehicles equipped with 2.3L and 3.0L engines have a dual cone blocking ring.
4. Install the first/second synchronizer. The identification hole in the sleeve must face first gear.
5. Install the first gear synchronizer blocking ring.
6. Install the first gear.
7. Install the first gear needle bearing.
8. Install the input bearing spacer.
9. Position the output shaft center bearing.
Using the special tools, press the output shaft center bearing into place.

Fig 7: Pressing Output Shaft Center Bearing
Courtesy of FORD MOTOR CO.

NOTE: Install the third/fourth synchronizer with the chamfer on the sleeve facing fourth gear.

Fig 8: Installing Third/Fourth Synchronizer

Courtesy of FORD MOTOR CO.

Install the following components:
1. The third gear needle bearing.
2. The third gear.
3. The third gear blocking ring.
4. The third/fourth synchronizer.
Install the following components:
1. The thrust washer.
2. The third/fourth synchronizer spacer.
3. The bearing outer snap ring.
Fig 9: Installing Bearing Outer Snap Ring
Courtesy of FORD MOTOR CO.
Check the third/fourth clutch hub end play.
- If clearance is not within specification, select the correct bearing outer snap ring.
Fig 10: Checking Third/Fourth Clutch Hub End Play
Courtesy of FORD MOTOR CO.

Fig 11: Bearing Outer Snap Ring Select Chart (1 Of 3)
Courtesy of FORD MOTOR CO.

Fig 12: Bearing Outer Snap Ring Select Chart (2 Of 3)
Courtesy of FORD MOTOR CO.

Fig 13: Bearing Outer Snap Ring Select Chart (3 Of 3)
Courtesy of FORD MOTOR CO.