Output Shaft: Disassembly

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.

Fig 1: Exploded View Of Output Shaft

Courtesy of FORD MOTOR CO.

Item	Part Number	Description
1	7025	Axial thrust washer
2	7A082	Snap ring
3	7124	3rd/4th gear synchronizer assembly
4	7107	3rd gear synchronizer ring assembly
5	-	Synchronizer ring (part of 7107)
6	-	Synchronizer outer cone (part of 7107)
7	-	Synchronizer inner cone (part of 7107)
8	7117	Spacer
9	7B340	3rd gear
10	7M037	3rd gear needle bearing
11	7061	Output shaft
12	7102	2nd gear
13	7M037	2nd gear needle bearing
14	7117	Spacer
15	7107B	2nd gear synchronizer ring assembly
16	-	Synchronizer inner cone (part of 7107)
17	-	Synchronizer outer cone (part of 7107)
18	-	Synchronizer ring (part of 7107)
19	7124A	1st/2nd gear synchronizer assembly
20	7A082A	Split ring
21	7A082A	Retainer
22	7107A	1st gear synchronizer ring assembly
23	-	Synchronizer ring (part of 7107)
24	-	Synchronizer outer cone (part of 7107)
25	-	Synchronizer inner cone (part of 7107)
26	7100	1st gear
27	7025	1st gear needle bearing
28	7025	Output shaft rear bearing
29	7L047	6th driven gear

NOTE: Slide the synchronizer sleeve up while removing the pressure pieces.

Remove the 3rd/4th gear synchronizer sleeve, the 3 pressure pieces and the axial thrust washer.
NOTE: Hand-tighten the Bearing Puller to prevent gear damage.

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

Using the Bearing Puller and a press, remove the 1st gear, the output shaft rear bearing and the 6th driven gear.
- Discard the output shaft bearing.
- Inspect the gears for wear or damage. Install new gears as necessary.
  
  Fig 2: 1st Gear, Output Shaft Rear Bearing And 6th Driven Gear
  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.
NOTE: Note the position of each synchronizer ring component before removal.

Remove the 1st gear synchronizer ring assembly.
- Inspect the 1st gear synchronizer ring assembly for wear or damage. Install a new synchronizer ring assembly as necessary.
  
  Fig 3: Locating 1st Gear Synchronizer Ring Assembly
  Courtesy of FORD MOTOR CO.
NOTE: Slide the synchronizer sleeve up while removing the pressure pieces.

Remove the 1st/2nd gear synchronizer sleeve and the 3 pressure pieces.

Fig 4: Locating 1st/2nd Gear Synchronizer Sleeve And Pressure Pieces
Courtesy of FORD MOTOR CO.
Remove the split ring and retainer.

Fig 5: Locating Split Ring And Retainer
Courtesy of FORD MOTOR CO.
Remove the 1st/2nd gear synchronizer hub.
NOTE: Note the position of each synchronizer ring component before removal.

Remove the 2nd gear synchronizer ring assembly.
- Inspect the 2nd gear synchronizer ring assembly for wear or damage. Install a new synchronizer ring assembly as necessary.
Remove the 2nd gear.
- Inspect 2nd gear for wear or damage. Install a new gear as necessary.
  
  Fig 6: Locating 2nd Gear
  Courtesy of FORD MOTOR CO.
Remove the 2nd gear needle bearing and the spacer.
- Inspect the needle bearing for wear or damage. Install a new needle bearing as necessary.
  
  Fig 7: Locating 2nd Gear Needle Bearing And Spacer
  Courtesy of FORD MOTOR CO.
Remove and discard the snap ring.
NOTE: Hand-tighten the Bearing Puller to prevent gear damage.

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

NOTE: Note the position of each synchronizer ring component before removal.

Using the Bearing Puller, remove the 3rd/4th gear synchronizer hub, the 3rd gear synchronizer ring assembly and the 3rd gear.
- Inspect the gear for wear or damage. Install a new gear as necessary.
  
  Fig 8: 3rd/4th Gear Synchronizer Hub, 3rd Gear Synchronizer Ring Assembly And 3rd Gear
  Courtesy of FORD MOTOR CO.
Remove the 3rd gear needle bearing and the spacer.
- Inspect the needle bearing for wear or damage. Install a new needle bearing as necessary.
  
  Fig 9: Locating 3rd Gear Needle Bearing
  Courtesy of FORD MOTOR CO.
Inspect the synchronizer assemblies for the following:
- Check for worn, nicked or broken teeth. Install a new synchronizer assembly as necessary.
- Check pressure pieces for wear or distortion. Check the pressure piece springs for distortion. Install a new synchronizer assembly as necessary.
Inspect the output shaft for scoring or worn or damaged splines. Install a new output shaft as necessary.