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Output Shaft: Assembly

WARNING: This page is about a different car, the 2003 Ford Focus. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Immerse the dual synchronizer units in a bath of transmission fluid prior to installation.
  1. Carefully clean and check all running surfaces and coat them with Manual transmission fluid before reassembly.
    2. NOTE: Install a new snap ring.
  2. Install the output shaft bearing cone.
    • Evenly heat the bearing cone to approximately 80°C and slide it onto the output shaft.
    • Install the snap-ring.
      Fig 1: Installing Output Shaft Bearing Cone
      G01613322Courtesy of FORD MOTOR CO.
    3. NOTE: Marking of selector ring installation position in relation to gear synchronizer hub.
  3. Assemble the gear synchronizer.
    1. Gear synchronizer hub
    2. Install the selector ring onto gear synchronizer hub.
    3. Insert the synchronizer lock.
    4. Insert the synchronizer spring.
      Fig 2: Assembling Gear Synchronizer
      G01613323Courtesy of FORD MOTOR CO.
    4. NOTE: Install a new snap ring.
  4. Install the first gear and reverse gear wheel onto the output shaft together with the gear synchronizer and the synchronizer unit.
    1. Gear wheel (first gear)
    2. Inner synchronizer ring
    3. Synchronizer cone
    4. Outer synchronizer ring
    5. First/second gear synchronizer with reverse gear wheel
    6. Snap-ring
      Fig 3: Installing First Gear And Reverse Gear Wheel Onto Output Shaft
      G01613324Courtesy of FORD MOTOR CO.
    5. NOTE: Reassemble synchronizer unit prior to installation.
    NOTE: Install new half round snap rings.
  5. Install the second gear wheel onto the output shaft together with the synchronizer unit.
    1. Outer synchronizer ring
    2. Synchronizer cone
    3. Inner synchronizer ring
    4. Gear wheel (second gear)
    5. Half-round snap-rings
    6. Closed retaining ring
      Fig 4: Installing Second Gear Wheel Onto Output Shaft Together With Synchronizer Unit
      G01613325Courtesy of FORD MOTOR CO.
    6. NOTE: The dual synchronizer as shown is used in case of servicing.
    Fig 5: Assembling Third Gear Synchronizer Unit
    G01613326Courtesy of FORD MOTOR CO.
  6. Assemble the third gear synchronizer unit.
    1. Gear wheel (third gear)
    2. Inner synchronizer ring
    3. Synchronizer cone
    4. Outer synchronizer ring
  7. Install the third gear synchronizer ring.
    1. Synchronizer ring.
    2. Gear wheel (third gear)
    Fig 6: Installing Third Gear Synchronizer Ring
    G01613327Courtesy of FORD MOTOR CO.
    8. NOTE: Install the selector ring with annular groove facing downwards and small hub collar facing upwards.
    NOTE: Install a new snap ring.
    Fig 7: Installing Third/Fourth Gear Synchronizer Unit
    G01613328Courtesy of FORD MOTOR CO.
  8. Install the third/fourth gear synchronizer unit
    1. Install the gear synchronizer, the third/fourth gear synchronizer unit and the third gear wheel.
    2. Install the snap-ring.
    9. NOTE: Install the ball bearing with annular groove facing outwards.
    NOTE: Install a new snap ring.
    Fig 8: Fourth Gear Wheel And Ball Bearing
    G01613329Courtesy of FORD MOTOR CO.
  9. Install the fourth gear wheel and the ball bearing.
    1. Install the synchronizer ring together with the fourth gear wheel.
    2. Using a press and a suitable tube, press on the ball bearing.
    • Install the snap-ring.
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