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Output Shaft: Assembly

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  1. Carry out the following before reassembling:
    • Inspect the gears for broken or cracked teeth. Check for unusual wear patterns.
    • Inspect the thrust washers for face wear, cracks, scoring and for signs of heat damage.
    • Inspect the bearings, bearing cups and the synchronizers for wear or damage.
    • Inspect the output shaft for scoring, wear or damaged splines. Install new components as necessary.
    • Always install new retaining rings.
  2. Lubricate all components with the recommended transmission fluid when reassembling.
    3. NOTE: Install the synchronizer assembly with the deeper center flange of the synchronizer hub facing toward the rear of the output shaft.
    NOTE: If installing the original synchronizer assembly, make sure the index marks made during disassembly are aligned.
    NOTE: It may be necessary to press the hub into position on the shaft.
    NOTE: Do not overextend the retaining ring. A damaged or overextended retaining ring will not allow 1st gear to fully seat.
  3. Position the output shaft with the output end facing upward. Install the 1st/2nd synchronizer assembly on the output shaft, then install a new retaining ring.
    4. Fig 1: Locating Synchronizer Assembly On Output Shaft
    GF0015880Courtesy of FORD MOTOR CO.
    Fig 2: Locating Overextend Retaining Ring
    GF0015881Courtesy of FORD MOTOR CO.
    NOTE: Align the blocking ring tabs with the synchronizer assembly.
  4. Install the 1st gear synchronizer blocking ring.
    5. Fig 3: Locating 1st Gear Synchronizer Blocking Ring
    GF0001098Courtesy of FORD MOTOR CO.
  5. Install the outer 1st gear synchronizer cone.
    6. Fig 4: Locating Outer 1st Gear Synchronizer Cone
    GF0015882Courtesy of FORD MOTOR CO.
  6. Install the inner 1st gear synchronizer cone. Rotate the inner cone till it is seated.
    7. Fig 5: Locating Inner 1st Gear Synchronizer Cone
    GF0015883Courtesy of FORD MOTOR CO.
    NOTE: Apply petroleum jelly to the bearing.
  7. Install the 1st gear needle bearing.
    8. Fig 6: Locating 1st Gear Needle Bearing
    GF0015884Courtesy of FORD MOTOR CO.
    NOTE: First gear is 127 mm (5 in) in diameter.
    NOTE: Rotate the gear to align the gear slots with the inner cone tabs.
    NOTE: Make sure that the gear fits over the retaining ring.
  8. Install 1st gear.
    9. Fig 7: Locating 1st Gear
    GF0015885Courtesy of FORD MOTOR CO.
  9. Install the reverse synchronizer cone.
    10. Fig 8: Locating Reverse Synchronizer Cone
    GF0015886Courtesy of FORD MOTOR CO.
  10. Install the reverse gear blocking ring.
    11. Fig 9: Locating Reverse Gear Blocking Ring
    GF0015887Courtesy of FORD MOTOR CO.
  11. Using the special tools, install the reverse gear bearing spacer.
    12. Fig 10: Locating Reverse Gear Bearing Spacer
    GF0015888Courtesy of FORD MOTOR CO.
  12. Install the reverse gear needle bearing.
    • Apply petroleum jelly to the bearing.
    13. Fig 11: Locating Reverse Gear Needle Bearing
    GF0015889Courtesy of FORD MOTOR CO.
  13. Install the reverse gear synchronizer assembly.
    14. Fig 12: Locating Reverse Gear Synchronizer Assembly
    GF0015890Courtesy of FORD MOTOR CO.
    NOTE: Rotate the gear to align the gear slots with the inner cone tabs.
    NOTE: Make sure the clutching teeth on the gear snap inside the sliding sleeve and the sliding sleeve is against the gear.
    NOTE: Function the synchronizer sleeve through the 2 positions to make sure of normal function.
  14. Install reverse gear.
    15. Fig 13: Locating Reverse Gear
    GF0015891Courtesy of FORD MOTOR CO.
    NOTE: Use petroleum jelly to hold the check ball in place.
  15. Install the check ball.
    16. Fig 14: Locating Check Ball
    GF0015892Courtesy of FORD MOTOR CO.
  16. Install the thrust washer. Be sure to align the slot in the washer with the check ball.
    17. Fig 15: Locating Thrust Washer
    GF0015893Courtesy of FORD MOTOR CO.
    NOTE: The flat side of 5th gear faces the output shaft end.
  17. Install the rear output shaft bearing, then 5th gear. Using the special tool, press both the bearing and gear into place.
    18. Fig 16: Locating Rear Output Shaft Bearing
    GF0015894Courtesy of FORD MOTOR CO.
    NOTE: Do not overextend the retaining ring.
  18. Install a new retaining ring.
  19. Reposition the output shaft with the input end facing upward.
  20. Install the 2nd gear synchronizer blocking ring. Rotate the blocking ring until seated.
    21. Fig 17: Locating 2nd Gear Synchronizer Blocking Ring
    GF0015895Courtesy of FORD MOTOR CO.
  21. Install the 2nd gear synchronizer outer cone and the second gear synchronizer inner cone.
    22. Fig 18: Locating 2nd Gear Synchronizer Outer Cone And Second Gear Synchronizer Inner Cone
    GF0015896Courtesy of FORD MOTOR CO.
    NOTE: Apply petroleum jelly to the bearing.
  22. Install the 2nd gear bearing.
    23. Fig 19: Locating 2nd Gear Bearing
    GF0015897Courtesy of FORD MOTOR CO.
    NOTE: Rotate the gear to align the gear slots with the inner cone tabs.
  23. Install 2nd gear.
    24. Fig 20: Locating 2nd Gear
    GF0015898Courtesy of FORD MOTOR CO.
    NOTE: Use petroleum jelly to hold the check ball in place.
  24. Install the check ball.
    25. Fig 21: Locating Check Ball
    GF0001099Courtesy of FORD MOTOR CO.
  25. Install the thrust washer. Be sure to align the slot in the washer with the check ball.
    26. Fig 22: Locating Thrust Washer
    GF0001100Courtesy of FORD MOTOR CO.
  26. Press the bearing spacer onto the output shaft.
    27. Fig 23: Locating Bearing Spacer Onto Output Shaft
    GF0015899Courtesy of FORD MOTOR CO.
    NOTE: Apply petroleum jelly to the bearing.
  27. Install the 3rd gear bearing.
    28. Fig 24: Locating 3rd Gear Bearing
    GF0015900Courtesy of FORD MOTOR CO.
  28. Install 3rd gear.
    29. Fig 25: Locating 3rd Gear
    GF0015901Courtesy of FORD MOTOR CO.
  29. Install the 3rd gear synchronizer blocking ring.
    30. Fig 26: Locating 3rd Gear Synchronizer Blocking Ring
    GF0015902Courtesy of FORD MOTOR CO.
    NOTE: Install the synchronizer body with the raised center facing downward.
    NOTE: Rotate the blocking ring until seated.
  30. Install the 3rd/4th gear synchronizer body.
    31. Fig 27: Locating 3rd/4th Gear Synchronizer Body
    GF0015903Courtesy of FORD MOTOR CO.
  31. Install a new retaining ring.
    32. Fig 28: Locating Retaining Ring
    GF0015871Courtesy of FORD MOTOR CO.
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