Output Shaft: Disassembly

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.

NOTE: Support the output shaft while using the press to prevent damage to the shaft or gears.

Using the Bearing Remover, press the Output Shaft Speed (OSS) sensor ring from the output shaft.

Fig 1: Locating Output Shaft Speed (OSS) Sensor Ring From Output Shaft

Courtesy of FORD MOTOR CO.

Using the Pinion Bearing Cone Remover, press 1st gear, the output shaft rear bearing and the 5th speed driven gear from the output shaft as an assembly.
- Discard the output shaft rear bearing.
- Inspect the gears for wear or damage. Install new gears as necessary.

Fig 2: Identifying Special Tool 205-D002

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Remove 1st gear needle bearing.
- Inspect the needle bearing for wear or damage. Install a new bearing as necessary.

Fig 3: Locating Needle Bearing

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

Remove the 1st gear bearing spacer.

Fig 4: Locating Gear Bearing Spacer

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Remove the 1st and 2nd speed synchronizer hub ball.

Fig 5: Locating 1st And 2nd Gear Synchronizer Hub Ball

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

Fig 6: Locating 1St Gear Synchronizer Inner Cone And 1St Gear Synchronizer Blocking Ring

Courtesy of FORD MOTOR CO.

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

Using a suitable tool, press the 3rd and 4th gear synchronizer assembly, the 3rd gear blocking ring and 3rd gear from the output shaft as an assembly.
- Inspect the gear for wear or damage. Install a new gear as necessary.
Disassemble and inspect the 3rd and 4th gear synchronizer assembly. For additional information, refer to Synchronizers .
Remove 3rd gear needle bearing.
- Inspect the needle bearing for wear or damage. Install a new bearing as necessary.

Fig 7: Locating 3rd Gear Needle Bearing

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Remove the snap ring and discard.

Fig 8: Locating Snap Ring

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Remove the 2nd gear bearing spacer.

Fig 9: Locating 2nd Gear Bearing Spacer

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Remove 2nd gear.
- Inspect the gear for wear or damage. Install a new gear as necessary.

Fig 10: Inspecting Gear For Wear Or Damage

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Remove 2nd gear needle bearing.
- Inspect the needle bearing for wear or damage. Install a new bearing as necessary.

Fig 11: Locating 2nd Gear Needle Bearing

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Remove the output shaft bearing snap ring and discard.

Fig 12: Locating Output Shaft Bearing Snap Ring

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Remove the 2nd gear synchronizer thrust washer.

Fig 13: Locating 2nd Gear Synchronizer Thrust Washer

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Remove the 2nd gear synchronizer inner cone, the 2nd gear synchronizer outer cone and the 2nd gear synchronizer blocking ring as an assembly.

Fig 14: Locating 2nd Gear Synchronizer Blocking Ring

Courtesy of FORD MOTOR CO.

NOTE: The 1st and 2nd gear synchronizer sliding sleeve, the hub and the output shaft are an assembly. Do not attempt to separate the hub from the output shaft. Only the synchronizer hub insert springs and the synchronizer hub inserts are available separately.

Remove the 1st and 2nd gear synchronizer sliding sleeve. Disassemble and inspect the 1st and 2nd gear synchronizer assembly. For additional information, refer to Synchronizers .