Output Shaft: Assembly

WARNING: This page is about a different car, the 2009 Ford Mustang. However, it is still accessible from the selected car via links, so may be relevant.

Lubricate all components with transmission fluid during assembly. Soak the blocking rings in transmission fluid for 10 minutes.
Install the 1st and 2nd gear synchronizer hub insert springs and the synchronizer inserts into the synchronizer hub. Install the sliding sleeve onto the hub.

NOTE: Align the slots in the synchronizer blocking ring with the tabs in the 1st and 2nd gear synchronizer.

Install the 2nd gear synchronizer blocking ring, the 2nd gear synchronizer outer cone and the 2nd gear synchronizer inner cone.

Fig 1: Locating 2nd Gear Synchronizer Blocking Ring

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Install the 2nd gear synchronizer thrust washer.

Fig 2: Locating 2nd Gear Synchronizer Thrust Washer

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Install the new output shaft bearing snap ring.

Fig 3: Locating 2nd Gear Synchronizer And 2nd Gear Synchronizer Outer Ring

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Install the 2nd gear needle bearing.

Fig 4: Locating 2nd Gear Needle Bearing

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Align the slots on 2nd gear with the tabs on the synchronizer blocking ring. Install 2nd gear.

Fig 5: Inspecting Gear For Wear Or Damage

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Fig 6: Aligning Slots On 2nd Gear With Tabs On Synchronizer Blocking Ring

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Install the 2nd gear bearing spacer.

Fig 7: Locating 2nd Gear Bearing Spacer

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Install a new snap ring.

Fig 8: Locating Snap Ring

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Install 3rd gear needle bearing.

Fig 9: Locating 3rd Gear Needle Bearing

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NOTE: Align the slots on 3rd gear with the tabs on the synchronizer blocking ring.

Position 3rd gear, the 3rd gear synchronizer blocking ring and the 3rd and 4th gear synchronizer assembly on the output shaft.

Fig 10: Locating Slots On 3rd Gear

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NOTE: Before pressing the components together, verify that the synchronizer hub faces the short end of the output shaft. Hold 3rd gear against the synchronizer to maintain the synchronizer blocking ring alignment.

Using a 1-1/2-inch deep well socket, press the 3rd gear, the 3rd gear synchronizer blocking ring and the 3rd and 4th gear synchronizer assembly onto the output shaft.

Fig 11: Locating 3rd Gear, 3rd Gear Synchronizer Blocking Ring And 3rd And 4th Gear Synchronizer Assembly

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NOTE: Reposition the output shaft on the press with the output end facing upward.

Install the 1st gear synchronizer blocking ring, the 1st gear synchronizer outer cone and the 1st gear synchronizer inner cone.

Fig 12: Locating 1St Gear Synchronizer Inner Cone And 1St Gear Synchronizer Blocking Ring

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Install the 1st and 2nd gear synchronizer hub ball.

Fig 13: Locating 1st And 2nd Gear Synchronizer Hub Ball

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NOTE: The 1st gear bearing spacer fits snugly on the output shaft.

Align the notch in the 1st gear bearing spacer and the 1st and 2nd gear synchronizer hub ball. Install the 1st gear bearing spacer.

Fig 14: Aligning Notch In 1st Gear Bearing Spacer & 1st And 2nd Gear Synchronizer Hub Ball

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Fig 15: Locating Gear Bearing Spacer

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Install the 1st gear needle bearing.

Fig 16: Locating Needle Bearing

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Align the slots on the synchronizer blocking ring and the slots on the 1st gear. Install 1st gear.

Fig 17: Aligning Slots On Synchronizer Blocking Ring & Slots On 1st Gear

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Install the output shaft rear bearing.

Fig 18: Installing Output Shaft Rear Bearing

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NOTE: Align the output shaft splines and the splines of the 5th speed driven gear or damage will occur.

Lubricate the splines of the 5th speed driven gear with petroleum jelly. Position the 5th speed driven gear on the output shaft. Using a capped length of pipe 31.7 mm (1.24 in) inside diameter by 356 mm (14.01 in) long, press on the 5th speed driven gear.

Fig 19: Aligning Output Shaft Splines And Splines Of 5th Speed Driven Gear

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Using the capped length of pipe 31.7 mm (1.24 in) inside diameter by 356 mm (14.01 in) long, press the OSS sensor ring on the output shaft.

Fig 20: Locating Output Shaft Speed (OSS) Sensor Ring On Output Shaft

Courtesy of FORD MOTOR CO.