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Output Shaft: Assembly

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  1. Lubricate all components with the recommended transmission fluid when reassembling.
  2. Using the special tools, press the new output shaft front bearing on the output shaft.
    3. Fig 1: Pressing New Output Shaft Front Bearing On Output Shaft Using Special Tools
    GF0001182Courtesy of FORD MOTOR CO.
  3. Install the 3rd gear bearing and the spacer.
    • Apply petroleum jelly to the bearing.
    4. Fig 2: Locating 3rd Gear Bearing & Spacer
    GF0001183Courtesy of FORD MOTOR CO.
  4. Install 3rd gear, the 3rd gear synchronizer double cones and the 3rd/4th gear synchronizer assembly. Position the output shaft with the output end facing upward. Using the special tool, press the 3rd/4th gear synchronizer assembly into place.
    • Install the synchronizer body with the groove facing 3rd gear.
    • Stop press operation before keys engage the blocking ring slots. Lift and rotate the 3rd gear and the blocking ring until the keys are seated in the blocking ring.
    5. Fig 3: Locating Synchronizer Body With Groove Facing 3rd Gear
    GF0001184Courtesy of FORD MOTOR CO.
  5. Install a new snap ring.
  6. Install the 2nd gear needle bearing.
    • Apply petroleum jelly to the bearing.
    7. Fig 4: Installing 2nd Gear Needle Bearing
    GF0001185Courtesy of FORD MOTOR CO.
  7. Install 2nd gear and the bearing spacer.
    8. Fig 5: Locating 2nd Gear Needle Bearing & Spacer
    GF0001178Courtesy of FORD MOTOR CO.
  8. Install the 2nd gear, the inner cone, the intermediate cone and the 2nd gear synchronizer blocking ring.
    • Align the blocking ring tabs with the 2nd gear slots.
    9. Fig 6: Locating 2nd Gear, Inner Cone, Intermediate Cone & 2nd Gear Synchronizer Blocking Ring
    GF0001177Courtesy of FORD MOTOR CO.
    Fig 7: Locating Inner Cone, Outer Cone, 2nd Gear Synchronizer Blocking Ring & Synchronizer Hub
    GF0001176Courtesy of FORD MOTOR CO.
  9. Install the 1st/2nd gear synchronizer hub assembly into place.
    • Install the synchronizer with the groove on the sleeve facing 1st gear.
    • Lift and rotate the 2nd gear and the blocking ring until the keys are seated in the blocking ring.
  10. Install the split washer.
    11. Fig 8: Installing Split Washer
    GF0001175Courtesy of FORD MOTOR CO.
  11. Install the 1st gear synchronizer sleeve and 3 synchronizer keys.
    12. Fig 9: Locating 1st Gear Synchronizer Sleeve & Synchronizer Keys
    GF0001174Courtesy of FORD MOTOR CO.
  12. Install the 1st gear synchronizer inner cone, the intermediate cone and the 1st gear synchronizer blocking ring.
    13. Fig 10: Locating 1st Gear Synchronizer Inner Cone, Intermediate Cone & 1st Gear Synchronizer Blocking Ring
    GF0001173Courtesy of FORD MOTOR CO.
  13. Install the 1st gear needle bearing.
    • Apply petroleum jelly to the bearing.
    14. Fig 11: Locating 1st Gear Needle Bearing
    GF0001186Courtesy of FORD MOTOR CO.
  14. Install 1st gear.
    • Rotate the gear to align the gear slots with the intermediate cone tabs.
  15. Using the special tool, install a new rear output shaft bearing.
    16. Fig 12: Installing New Rear Output Shaft Bearing Using Special Tool
    GF0001187Courtesy of FORD MOTOR CO.
  16. Using the special tools, install the 5th driven gear.
    17. Fig 13: Installing 5th Driven Gear Using Special Tools
    GF0001188Courtesy of FORD MOTOR CO.
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