Output Shaft: Assembly

WARNING: This page is about a different car, the 2013 Ford Mustang. However, it is still accessible from the selected car via links, so may be relevant.

Lubricate all components with clean transmission fluid when reassembling.
Position the 3rd/4th gear synchronizer hub and the 3rd gear synchronizer ring assembly on the Bearing Puller.
- Align the synchronizer ring tabs with the synchronizer hub slots.
NOTE: Align the synchronizer ring tabs with the gear slots.

Install the 3rd gear, the spacer and the 3rd gear needle bearing.
1. 3rd gear
2. Spacer
3. 3rd gear needle bearing
NOTE: Align the synchronizer hub splines with the output shaft splines before using the press or damage to the synchronizer hub can occur.

Using the Bearing Puller, press the output shaft into place.
Install a new snap ring.
Install the 2nd gear needle and the bearing spacer.
- Apply petroleum jelly to the bearing.
  
  Fig 1: Locating 2nd Gear Needle And Bearing Spacer
  Courtesy of FORD MOTOR CO.
Install the 2nd gear.

Fig 2: Locating 2nd Gear
Courtesy of FORD MOTOR CO.
Install the 2nd gear synchronizer ring assembly.
- Align the synchronizer ring tabs with the 2nd gear slots.
  
  Fig 3: Locating 2nd Gear Synchronizer Ring Assembly
  Courtesy of FORD MOTOR CO.
Install the 1st/2nd gear synchronizer hub assembly into place.
Install the split ring and retainer.

Fig 4: Locating Split Ring And Retainer
Courtesy of FORD MOTOR CO.
NOTE: The marked side of the 1st/2nd gear synchronizer sleeve must face the 2nd gear, or transmission shifting concerns will occur.

NOTE: Slide the synchronizer sleeve down while installing the pressure pieces.

Install the 1st/2nd gear synchronizer sleeve and the 3 pressure pieces.
- Install the 1st/2nd gear synchronizer sleeve with the 2nd gear mark facing 2nd gear.
  
  Fig 5: Locating 1st/2nd Gear Synchronizer Sleeve And Pressure Pieces
  Courtesy of FORD MOTOR CO.
Install the 1st gear synchronizer ring assembly.
- Align the synchronizer ring tabs with the synchronizer hub slots.
  
  Fig 6: Locating 1st Gear Synchronizer Ring Assembly
  Courtesy of FORD MOTOR CO.
Install the 1st gear needle bearing.
- Apply petroleum jelly to the bearing.
Install the 1st gear.
- Align the synchronizer ring tabs with the 1st gear slots.
Using the Bearing Tube Remover/Installer, install a new rear output shaft bearing.

Fig 7: Rear Output Shaft Bearing Remover/Installer
Courtesy of FORD MOTOR CO.
Using the Bearing Tube Remover/Installer, install the 6th driven gear.

Fig 8: 6th Driven Gear Using Bearing Tube Remover/Installer
Courtesy of FORD MOTOR CO.
NOTE: The marked side of the 3rd/4th gear synchronizer sleeve must face the 4th gear, or transmission shifting concerns will occur.

NOTE: Slide the synchronizer sleeve on while installing the pressure pieces.

Install the 3rd/4th gear synchronizer sleeve, the 3 pressure pieces and the axial thrust washer.
- Install the 3rd/4th gear synchronizer sleeve with the 4th gear mark facing the 4th gear.
- Apply petroleum jelly to hold the axial thrust washer.