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.

Remove the retaining ring above 5th gear.

Fig 1: Locating Retaining Ring Above 5th Gear

Courtesy of FORD MOTOR CO.

CAUTION: Hand-tighten the special tool to prevent gear damage.

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

Using the special tool, press 5th gear, the spacer, the output shaft bearing and reverse gear from the output shaft.
- Discard the output shaft bearing.

Fig 2: Removing 5th Gear, Spacer, Output Shaft Bearing And Reverse Gear From Output Shaft

Courtesy of FORD MOTOR CO.

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

Fig 3: Locating Reverse Gear Needle Bearing

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Remove the check ball and the blocking ring.
- Inspect the blocking ring for wear or damage. Install new blocking rings as necessary.

Fig 4: Locating Check Ball And Blocking Ring

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NOTE: Install the special tool with the flat side facing 1st gear.

Using the special tools, press the bearing spacer, the reverse gear synchronizer cone and 1st gear from the output shaft.

Fig 5: Identifying Bearing Spacer, Reverse Gear Synchronizer Cone And 1st Gear From Output Shaft

Courtesy of FORD MOTOR CO.

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

Fig 6: Locating 1st Gear Needle Bearing

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Remove the 1st gear synchronizer inner cone, the 1st gear synchronizer outer cone and the 1st gear synchronizer blocking ring.
- Inspect all components for wear or damage. Install new components as necessary.

Fig 7: Locating 1st Gear Synchronizer Inner Cone

Courtesy of FORD MOTOR CO.

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

Remove and discard the retaining ring.

Fig 8: Locating Retaining Ring

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Remove the 3rd/4th synchronizer hub.

Fig 9: Locating 3rd/4th Synchronizer Hub

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Remove the 3rd/4th blocking ring.

Fig 10: Locating 3rd/4th Blocking Ring

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Remove the 3rd gear.
- Inspect the gear for wear or damage. Install a new gear as necessary.

Fig 11: Locating Input Shaft Gear

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NOTE: Inspect the needle bearing for wear or damage. Install a new needle bearing as necessary.

Remove the 3rd gear needle bearing.

Fig 12: Locating Gear Needle Bearing

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NOTE: Install the special tool behind 2nd gear with the flat side of the tool facing 2nd gear.

Using the special tool, remove the spacer, 2nd gear thrust washer and 2nd gear.
- Inspect the gear for wear or damage. Install a new gear as necessary.

Fig 13: Locating Thrust Washer And Gear

Courtesy of FORD MOTOR CO.

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

Fig 14: Locating Check Ball And 2nd Gear Needle Bearing

Courtesy of FORD MOTOR CO.

Remove the 2nd gear synchronizer inner cone, 2nd gear synchronizer outer cone and the 2nd gear synchronizer blocking ring.
- Inspect all components for wear or damage. Install new components as necessary.

Fig 15: Locating 2nd Gear Synchronizer Outer Cone And 2nd Gear Synchronizer Blocking Ring

Courtesy of FORD MOTOR CO.

Remove the snap ring, then using the special tool, press off the 1st/2nd gear synchronizer.

Fig 16: Identifying Special Tool 205-D002

Courtesy of FORD MOTOR CO.