Disassembly And Assembly Of Subassemblies: Countershaft: Disassembly

Place the special tool in a vise, then install the countershaft with the countershaft locknut facing upward. Loosen the countershaft locknut. Do not remove at this time.

Fig 1: Placing Special Tool In Vise
Courtesy of FORD MOTOR CO.

NOTE: Place the Bearing/Oil Seal Plate in a vise.

Install the countershaft in the bearing/oil seal plate with the countershaft bearing facing upward.
Using the special tools, remove the countershaft bearing.
- Install new bearings and cups in a set only. Do not install one without the other.
  
  Fig 2: Installing Special Tool
  Courtesy of FORD MOTOR CO.
Remove the spacer.

Fig 3: Removing Spacer
Courtesy of FORD MOTOR CO.
Remove the countershaft third gear.
- Inspect the gear for wear or damage. Install a new gear as necessary.
  
  Fig 4: Removing Countershaft Third Gear
  Courtesy of FORD MOTOR CO.
Remove the countershaft second gear.
- Inspect the gear for wear or damage. Install a new gear as necessary.
  
  Fig 5: Removing Countershaft Second Gear
  Courtesy of FORD MOTOR CO.
Remove the second gear needle bearing and the needle bearing inner race.
- Inspect the bearing for wear or damage. Install a new bearing as necessary.
  
  Fig 6: Removing Second Gear Needle Bearing
  Courtesy of FORD MOTOR CO.
Remove the first and second gear synchronizer assembly.

Fig 7: Removing First And Second Gear Synchronizer Assembly
Courtesy of FORD MOTOR CO.
Disassemble the first and second gear synchronizer assembly.
- Inspect the synchronizer for wear or damage. Repair or install a new synchronizer as necessary.
  
  Fig 8: Exploded View Of First And Second Gear Synchronizer Assembly
  Courtesy of FORD MOTOR CO.
Remove the countershaft first gear.
- Inspect the gear for wear or damage. Install a new gear as necessary.
  
  Fig 9: Removing Countershaft First Gear
  Courtesy of FORD MOTOR CO.
Remove the first gear needle bearing.
- Inspect the bearing for wear or damage. Install a new bearing as necessary.
  
  Fig 10: Removing First Gear Needle Bearing
  Courtesy of FORD MOTOR CO.
Rotate the countershaft in the bearing/oil seal plate.
Remove the countershaft locknut.

Fig 11: Removing Countershaft Locknut
Courtesy of FORD MOTOR CO.
Using the special tools, remove the countershaft front bearing.
- Install new bearings and cups in a set only. Do not install one without the other.
  
  Fig 12: Installing Special Tool
  Courtesy of FORD MOTOR CO.
Remove the countershaft fifth gear.
- Inspect the gear for wear or damage. Install a new gear as necessary.
  
  Fig 13: Removing Countershaft Fifth Gear
  Courtesy of FORD MOTOR CO.
Remove the fifth gear needle bearing.
- Inspect the bearing for wear or damage. Install a new bearing as necessary.
  
  Fig 14: Removing Fifth Gear Needle Bearing
  Courtesy of FORD MOTOR CO.
Remove the synchronizer blocking ring.

Fig 15: Removing Synchronizer Blocking Ring
Courtesy of FORD MOTOR CO.
Remove the thrust washer.

Fig 16: Removing Thrust Washer
Courtesy of FORD MOTOR CO.
Remove the two piece thrust washer.

Fig 17: Removing Two Piece Thrust Washer
Courtesy of FORD MOTOR CO.
Remove the fifth/reverse synchronizer body.

Fig 18: Removing Fifth/Reverse Synchronizer Body
Courtesy of FORD MOTOR CO.
Disassemble the fifth/reverse synchronizer assembly.
- Inspect the synchronizer for wear or damage. Repair or install a new synchronizer as necessary.
  
  Fig 19: Exploded View Of Fifth/Reverse Synchronizer Assembly
  Courtesy of FORD MOTOR CO.
Remove the synchronizer blocking ring.

Fig 20: Removing Synchronizer Blocking Ring
Courtesy of FORD MOTOR CO.
Remove the countershaft reverse gear.
- Inspect the gear for wear or damage. Install a new gear as necessary.
  
  Fig 21: Removing Countershaft Reverse Gear
  Courtesy of FORD MOTOR CO.
Remove reverse gear needle bearing.
- Inspect the bearing for wear or damage. Install a new bearing as necessary.
  
  Fig 22: Removing Reverse Gear Needle Bearing
  Courtesy of FORD MOTOR CO.

CAUTION: To prevent damage, inspect the surface of the countershaft in the area of the bearing race to make sure it is smooth and free of burrs.

Inspect the countershaft for damage or wear. Install a new shaft as necessary.