Disassembly And Assembly

WARNING: This page is about a different car, the 2007 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: Locating 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: Locating 4th Gear Synchronizer Blocking Ring And Snap Ring

Courtesy of FORD MOTOR CO.

Remove the following components:
- Remove the spacer.
- Remove the thrust washer.
- Remove the 3rd/4th gear synchronizer assembly.
- Remove the 3rd gear synchronizer blocking ring.
- Inspect all components for wear or damage. Install new components as necessary.

Fig 3: Identifying Spacer And Thrust Washer

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: Locating 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: Locating 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: Locating 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: Locating 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: Locating 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: Locating 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: Identifying 1st Gear Synchronizer Blocking Ring
Courtesy of FORD MOTOR CO.
Remove the 1st/2nd gear synchronizer assembly and the 2nd gear synchronizer blocking ring.

Fig 11: Locating 1st/2nd Gear Synchronizer Assembly

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: Locating Inner And Outer 2nd Gear Synchronizer Blocking Rings
Courtesy of FORD MOTOR CO.
Remove 2nd gear.

Fig 13: Locating 2nd Gear

Courtesy of FORD MOTOR CO.

Remove the 2nd gear needle bearing.

Fig 14: Locating 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
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.