Disassembly and 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.

Remove the input shaft needle bearing.
- Place the output shaft in the holder with the input end facing upward.
Fig 1: Removing Input Shaft Needle Bearing
Courtesy of FORD MOTOR CO.
Remove the snap ring and the 4th gear synchronizer blocking ring. Discard the snap ring.
- Inspect the blocking ring for wear or damage. Install a new blocking ring as necessary.
Fig 2: Removing Snap Ring And 4th Gear Synchronizer Blocking Ring
Courtesy of FORD MOTOR CO.
Remove the following components:
1. Remove the spacer.
2. Remove the thrust washer.
3. Remove the 3rd/4th gear synchronizer assembly.
4. Remove the 3rd gear synchronizer blocking ring.
- Inspect all components for wear or damage. Install new components as necessary.
Fig 3: Removing 3rd Spacer, Thrust Washer, 3rd/4th Gear Synchronizer Assembly And 3rd Gear Synchronizer Blocking Ring
Courtesy of FORD MOTOR CO.
Remove the inner and outer 3rd gear synchronizer blocking rings.
- Inspect the blocking rings for wear or damage. Install new blocking rings as necessary.
Fig 4: Removing Inner And Outer 3rd Gear Synchronizer Blocking Rings
Courtesy of FORD MOTOR CO.
Remove 3rd gear.
- Inspect the gear for wear or damage. Install a new gear as necessary.
Fig 5: Removing 3rd Gear
Courtesy of FORD MOTOR CO.
Remove the 3rd gear needle bearing.
- Inspect the bearing for wear or damage. Install a new bearing as necessary.
Fig 6: Removing 3rd Gear Needle Bearing
Courtesy of FORD MOTOR CO.
Place the shaft on a press, with the output end facing upward. Using the special tool, remove the output shaft bearing.
- Inspect the bearing for wear or damage. Install a new bearing as necessary.
Fig 7: Using Special Tool To Remove Output Shaft Bearing
Courtesy of FORD MOTOR CO.
Remove the sleeve and 1st gear.
- Inspect 1st gear for wear or damage. Install a new gear as necessary.
Fig 8: Removing Sleeve And 1st Gear
Courtesy of FORD MOTOR CO.
Remove the 1st gear needle bearing.
- Inspect 1st gear for wear or damage. Install a new gear as necessary.
Fig 9: Removing 1st Gear Needle Bearing
Courtesy of FORD MOTOR CO.
Remove the following components:
1. Remove the 1st gear synchronizer blocking ring.
2. Remove the outer synchronizer blocking ring.
3. Remove the inner synchronizer blocking ring.
- Inspect the blocking rings for wear or damage. Install new blocking rings as necessary.
Fig 10: Removing 1st Gear Synchronizer Blocking Ring, Outer Synchronizer Blocking Ring And Inner Synchronizer Blocking Ring
Courtesy of FORD MOTOR CO.
Remove the 1st/2nd gear synchronizer assembly and the 2nd gear synchronizer blocking ring.

Fig 11: Removing 1st/2nd Gear Synchronizer Assembly And 2nd Gear Synchronizer Blocking Ring
Courtesy of FORD MOTOR CO.
Remove the inner and outer 2nd gear synchronizer blocking rings.
- Inspect the blocking rings for wear or damage. Install new blocking rings as necessary.
Fig 12: Removing Inner And Outer 2nd Gear Synchronizer Blocking Rings
Courtesy of FORD MOTOR CO.
Remove 2nd gear.

Fig 13: Removing 2nd Gear
Courtesy of FORD MOTOR CO.
Remove the 2nd gear needle bearing.

Fig 14: Removing 2nd Gear Needle Bearing
Courtesy of FORD MOTOR CO.
Using the special tool, check the output shaft runout.
- Check the runout in several places along the output shaft. If runout exceeds specification, install a new output shaft.
Fig 15: Checking Output Shaft Runout Using Special Tool
Courtesy of FORD MOTOR CO.
Check the clearance between the synchronizer blocking rings and the gear clutching teeth.
- Place the synchronizer blocking ring on the gear. Insert a feeler gauge and measure the clearance, while applying pressure and rotating the ring. The clearance should be the same around the entire circumference.
  - If the clearance is less than 0.8 mm (0.03 in), install a new blocking ring or gear as necessary.
Fig 16: Checking Clearance Between Synchronizer Blocking Rings And Gear Clutching Teeth
Courtesy of FORD MOTOR CO.