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Output Shaft: 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.
  1. Lubricate all output shaft components with the recommended lubricant during reassembly.
  2. Install the 2nd gear needle bearing.
    3. Fig 1: Locating 2nd Gear Needle Bearing
    GF0003961Courtesy of FORD MOTOR CO.
  3. Install 2nd gear.
    4. Fig 2: Locating 2nd Gear
    GF0003960Courtesy of FORD MOTOR CO.
  4. 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: Locating Inner And Outer 2nd Gear Synchronizer Blocking Rings
    GF0003959Courtesy of FORD MOTOR CO.
  5. 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: Locating 1st/2nd Gear Synchronizer Assembly
    GF0003958Courtesy of FORD MOTOR CO.
  6. 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.
    Fig 5: Identifying Inner And Outer Synchronizer Blocking Ring
    GF0003957Courtesy of FORD MOTOR CO.
    • Align the tabs on the inner blocking ring with the spaces on the 2nd gear synchronizer blocking ring.
  7. Install the 1st gear needle bearing.
    8. Fig 6: Locating 1st Gear Needle Bearing
    GF0003956Courtesy of FORD MOTOR CO.
  8. Install 1st gear and the sleeve.
    • Align the tabs on the outer blocking ring with the notches in the gear.
    Fig 7: Locating Sleeve And 1st Gear
    GF0003955Courtesy of FORD MOTOR CO.
    9. 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
    GF0003964Courtesy of FORD MOTOR CO.
  9. Using the special tools, install the output shaft bearing.
    • Make sure the bearing is installed against 1st gear.
    10. NOTE: Rotate the shaft so the output end is facing downward
  10. Install the 3rd gear needle bearing.
    11. Fig 9: Locating 3rd Gear Needle Bearing
    GF0003953Courtesy of FORD MOTOR CO.
  11. Install 3rd gear.
    12. Fig 10: Locating 3rd Gear
    GF0003952Courtesy of FORD MOTOR CO.
  12. 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: Locating Inner And Outer 3rd Gear Synchronizer Blocking Rings
      GF0003951Courtesy of FORD MOTOR CO.
  13. 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
  14. 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: Locating 4th Gear Synchronizer Blocking Ring And Snap Ring
    GF0003949Courtesy of FORD MOTOR CO.
  15. Using a feeler gauge, check the 3rd/4th synchronizer hub end play.
    • If the clearance is not within specifications, select the correct snap ring.
      • Fig 13: Checking 3rd/4th Synchronizer Hub End Play
      GF0003965Courtesy of FORD MOTOR CO.
    • 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)
  16. Install the input shaft needle bearing.
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