Output Shaft and Bearing: Assembly

WARNING: This page is about a different car, the 2004 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.

First gear synchronizer blocking ring (R1 model)
Third gear synchronizer blocking ring (R1 and R1 HD models)
First gear synchronizer blocking ring (R1 HD model)

Second and fourth gear synchronizer ring (R1 and R1 HD models)

GEAR SPECIFICATIONS

Gear	2.3L/3.0L		4.0L
Gear	Material	Part Number	Material	Part Number
1st	Single Carbon	1L24-7107-AA	Single Carbon	1L54-7107-DA
2nd	Dual Carbon	1L24-7124-BA	Single Carbon	1L54-7107-DA
3rd	Single Carbon	1L54-7107-BA	Single Carbon	1L54-7107-BA
4th	Single Carbon	1L54-7107-DA	Single Carbon	1L54-7107-DA
5th	Single Brass	1L54-7107-EA	Single Brass	1L54-7107-EA
Reverse	Single Carbon	1L54-7107-CA	Single Carbon	1L54-7107-CA

Fig 2: Identifying Synchronizer Blocking Rings

Courtesy of FORD MOTOR CO.

Inspect the synchronizer blocking rings for correct contact with the cone surface of first gear.

Fig 3: Inspecting Synchronizer Blocking Rings For Correct Contact
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 4: Measuring Blocking Ring Clearance
  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.
  
  Fig 5: Installing Second Synchronizer Blocking Ring
  Courtesy of FORD MOTOR CO.
Using the special tools, press the output shaft center bearing into place.

Fig 6: Pressing Output Shaft Center Bearing Into Place
Courtesy of FORD MOTOR CO.

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

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.
  
  Fig 7: Installing Third Gear Components
  Courtesy of FORD MOTOR CO.
Install the following components:
1. The thrust washer.
2. The third/fourth synchronizer spacer.
3. The bearing outer snap ring.
  
  Fig 8: Installing Thrust Washer, Third/Fourth Synchronizer Spacer And 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.

BEARING OUTER SNAP RING SELECT CHART

Part Number	Thickness
E8TZ-7030-A	1.50 mm (0.0590 in)
E8TZ-7030-B	1.55 mm (0.0610 in)
E8TZ-7030-C	1.60 mm (0.0629 in)
E8TZ-7030-D	1.65 mm (0.0649 in)
E8TZ-7030-E	1.70 mm (0.0669 in)
E8TZ-7030-F	1.75 mm (0.0688 in)
E8TZ-7030-G	1.80 mm (0.0708 in)
E8TZ-7030-H	1.85 mm (0.0728 in)
E8TZ-7030-J	1.90 mm (0.0748 in)
E8TZ-7030-K	1.95 mm (0.0767 in)

Fig 9: Checking Third/Fourth Clutch Hub End Play

Courtesy of FORD MOTOR CO.