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Output Shaft and Bearing: Assembly

WARNING: This page is about a different car, the 2007 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
  1. Using the special tool, check the output shaft runout.
    Fig 1: Checking Output Shaft Runout
    GF0010546Courtesy of FORD MOTOR CO.
    • Check runout in several places along the output shaft. If runout exceeds 0.05 mm (0.002 in) install a new output shaft.
  2. Identify the synchronizer blocking ring.
    Fig 2: Identifying Synchronizer Blocking Ring
    GF0010547Courtesy of FORD MOTOR CO.
    • First gear synchronizer blocking ring (R1 model)
    • First gear synchronizer blocking ring (R1 HD model)
    • Second and 4th gear synchronizer ring (R1 and R1 HD models)
      Gear 2.3L/3.0L 4.0L
      Material Part Number Material Part Number
      1st Single Carbon 1L24-7107-AA Single Carbon 1L54-7107-DA
      2nd Dual Carbon 1L24-7124-BA Single Carbon 1L54-7107-DA
      3rd Single Carbon 1L54-7107-DA Single Carbon 1L54-7107-DA
      4th Single Carbon 1L54-7107-DA Single Carbon 1L54-7107-DA
      5th Single Brass 1L54-7107-EA Single Brass 1L54-7107-EA
      Reverse Single Carbon 1L54-7107-CA Single Carbon 1L54-7107-CA
  3. Inspect the synchronizer blocking rings for correct contact with the cone surface of 1st gear.
    Fig 3: Locating Synchronizer Blocking Rings
    GF0010548Courtesy of FORD MOTOR CO.
  4. Inspect the synchronizer blocking rings for wear on 2nd gear.
    • Vehicles equipped with 2.3L and 3.0L engines have dual cone blocking rings. Measure both blocking rings.
      Fig 4: Measuring Blocking Rings
      GF0010549Courtesy of FORD MOTOR CO.
    • If clearance is less than specification, install a new blocking ring or gear.
  5. Assemble the 1st and 2nd gear assembly as follows.
    Fig 5: Identifying 1st & 2nd Gear Assembly Components
    GF0010550Courtesy of FORD MOTOR CO.
    • Install the 2nd gear needle bearing.
    • Install the 2nd gear.
    • Install the 2nd synchronizer blocking ring.
      • Vehicles equipped with 2.3L and 3.0L engines have a dual cone blocking ring.
    • Install the 1st gear synchronizer blocking ring.
    • Install the 1st gear.
    • Install the 1st gear needle bearing.
    • Install the input bearing spacer.
    • Position the output shaft center bearing.
  6. Using the special tools, press the output shaft center bearing into place.
    Fig 6: Identifying Special Tool (308-024, 205-004, 205-090)
    GF0010551Courtesy of FORD MOTOR CO.
    7. NOTE: If necessary, use press to install the 3rd/4th synchronizer.
    Fig 7: Identifying 3rd/4th Synchronizer Components
    GF0010552Courtesy of FORD MOTOR CO.
  7. Install the following components:
    • The 3rd gear needle bearing.
    • The 3rd gear.
    • The 3rd gear blocking ring.
    • The 3rd/4th synchronizer.
  8. Install the following components:
    • The thrust bearing.
    • The 3rd/4th synchronizer spacer.
      Fig 8: Identifying 3rd/4th Synchronizer Spacer
      GF0010553Courtesy of FORD MOTOR CO.
    • The bearing outer snap ring.
  9. Check the 3rd/4th clutch hub end play.
    Fig 9: Checking 3rd/4th Clutch Hub End Play
    GF0010554Courtesy of FORD MOTOR CO.
    • If clearance is not within specification, select the correct bearing outer snap ring.
      BEARING OUTER SNAP RING SELECT CHART

      Part Number Thickness
      E8TZ-7030-A 1.50 mm (0.0590 in)
      E8TZ-7030-B 1.55 mm (0.0610 in)
      E8TZ-7030-C 1.60 mm (0.0629 in)
      E8TZ-7030-D 1.65 mm (0.0649 in)
      E8TZ-7030-E 1.70 mm (0.0669 in)
      E8TZ-7030-F 1.75 mm (0.0688 in)
      E8TZ-7030-G 1.80 mm (0.0708 in)
      E8TZ-7030-H 1.85 mm (0.0728 in)
      E8TZ-7030-J 1.90 mm (0.0748 in)
      E8TZ-7030-K 1.95 mm (0.0767 in)
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