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Output Shaft: Disassembly

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  1. Remove the 3rd/4th synchronizer sleeve.
    2. 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.
  2. Using the special tool and a press, remove 1st gear, the output shaft rear bearing and the 5th driven gear.
    • Discard the output shaft bearing.
    • Inspect the gears for wear or damage. Install a new gear as necessary.
    3. Fig 1: Locating 1st Gear, Output Shaft Rear Bearing & 5th Driven Gear
    GF0001172Courtesy of FORD MOTOR CO.
  3. Remove the 1st gear needle bearing.
    • Inspect the needle bearing for wear or damage. Install a new needle bearing as necessary.
  4. Remove the 1st gear synchronizer inner cone, the outer cone and the blocking ring.
    • Inspect all components for wear or damage. Install new components as necessary.
    5. Fig 2: Locating 1st Gear Synchronizer Inner Cone, Intermediate Cone & 1st Gear Synchronizer Blocking Ring
    GF0001173Courtesy of FORD MOTOR CO.
  5. Remove the synchronizer sleeve and the 3 synchronizer keys.
    6. Fig 3: Locating 1st Gear Synchronizer Sleeve & Synchronizer Keys
    GF0001174Courtesy of FORD MOTOR CO.
  6. Remove the split washer.
    7. Fig 4: Installing Split Washer
    GF0001175Courtesy of FORD MOTOR CO.
  7. Remove the 1st/2nd gear synchronizer hub.
  8. Remove the inner cone, the outer cone, the 2nd gear synchronizer blocking ring and the synchronizer hub.
    • Inspect all synchronizer components for wear or damage. Install new components as necessary.
    9. Fig 5: Locating Inner Cone, Outer Cone, 2nd Gear Synchronizer Blocking Ring & Synchronizer Hub
    GF0001176Courtesy of FORD MOTOR CO.
  9. Remove 2nd gear.
    • Inspect 2nd gear for wear or damage. Install a new gear as necessary.
    10. Fig 6: Locating 2nd Gear, Inner Cone, Intermediate Cone & 2nd Gear Synchronizer Blocking Ring
    GF0001177Courtesy of FORD MOTOR CO.
  10. Remove the 2nd gear needle bearing and the spacer.
    • Inspect the needle bearing for wear or damage. Install a new needle bearing as necessary.
    11. Fig 7: Locating 2nd Gear Needle Bearing & Spacer
    GF0001178Courtesy of FORD MOTOR CO.
    NOTE: Reposition the output shaft on the press with the input shaft end facing upward.
  11. Remove and discard the snap ring, then using the special tool, remove the 3rd/4th gear synchronizer assembly, the 3rd gear synchronizer double cone and the 3rd gear.
    • Inspect the gear for broken or cracked teeth. Install a new gear as necessary.
    • Inspect all synchronizer components for wear or damage. Install new components as necessary.
    12. Fig 8: Locating 3rd/4th Gear Synchronizer Assembly, 3rd Gear Synchronizer Double Cone & 3rd Gear
    GF0001179Courtesy of FORD MOTOR CO.
  12. Remove the 3rd gear needle bearing and the spacer.
    • Inspect the needle bearing for wear or damage. Install a new needle bearing as necessary.
    13. Fig 9: Locating 3rd Gear Needle Bearing & Space
    GF0001180Courtesy of FORD MOTOR CO.
    NOTE: Install the special tool with the flat side facing the bearing.
  13. Using the special tool, press the output shaft front bearing from the output shaft. Discard the bearing.
    14. Fig 10: Pressing Output Shaft Front Bearing From Output Shaft Using Special Tool
    GF0001181Courtesy of FORD MOTOR CO.
  14. Inspect the synchronizers.
    • Check for worn, nicked or broken teeth. Install a new synchronizer as necessary.
    • Check keys for wear or damage. Install a new synchronizer as necessary.
  15. Inspect the synchronizer blocking rings.
    • Check for wear or damage. Install new synchronizer blocking rings as necessary.
    • Check the clearance between the synchronizer blocking ring and the gear.
      • Position the blocking ring onto the gear. Make sure the correct blocking ring is measured with the correct gear and that the blocking ring is fully seated on the gear.
      • Insert a feeler gauge and measure the clearance, while applying pressure and rotating the blocking ring. The measurement should be the same around the entire circumference. If the clearance is less than 0.38 mm (0.015 in), install new blocking rings.
    16. Fig 11: Measuring Clearance Between Synchronizer Blocking Ring And Gear
    GF0015784Courtesy of FORD MOTOR CO.
  16. Inspect the output shaft for scoring or worn or damaged splines. Install a new output shaft as necessary.
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