Disassembly And Assembly Of Subassemblies: Countershaft: Assembly

CAUTION: Do not reassemble the countershaft dry. Apply lubricant throughout the assembly procedure.

Lubricate all countershaft components with the recommended transmission lubricant.
Position the countershaft in the special tool.

Fig 1: Positioning Countershaft In Special Tool
Courtesy of FORD MOTOR CO.
Install the reverse gear needle bearing.

Fig 2: Installing Reverse Gear Needle Bearing
Courtesy of FORD MOTOR CO.
Install the countershaft reverse gear.

Fig 3: Installing Countershaft Reverse Gear
Courtesy of FORD MOTOR CO.
Install the reverse synchronizer blocking ring.
- The reverse synchronizer blocking ring has a carbon surface.
  
  Fig 4: Installing Reverse Synchronizer Blocking Ring
  Courtesy of FORD MOTOR CO.
Install the fifth/reverse synchronizer assembly.
- Make sure to align the notches on the synchronizer body with the tabs on the synchronizer ring.
  
  Fig 5: Installing Fifth/Reverse Synchronizer Assembly
  Courtesy of FORD MOTOR CO.
Install the fifth synchronizer blocking ring.
- The fifth synchronizer blocking ring is brass.
  
  Fig 6: Installing Fifth Synchronizer Blocking Ring
  Courtesy of FORD MOTOR CO.
Install the two piece thrust washer.

Fig 7: Installing Two Piece Thrust Washer
Courtesy of FORD MOTOR CO.
Install the thrust washer.

Fig 8: Installing Thrust Washer
Courtesy of FORD MOTOR CO.
Install the fifth gear needle bearing.

Fig 9: Installing Fifth Gear Needle Bearing
Courtesy of FORD MOTOR CO.
Install the countershaft fifth gear.

Fig 10: Installing Countershaft Fifth Gear
Courtesy of FORD MOTOR CO.
Using the special tools, install the countershaft front bearing.

Fig 11: Installing Countershaft Front Bearing
Courtesy of FORD MOTOR CO.
Install the countershaft locknut.

Fig 12: Installing Countershaft Locknut
Courtesy of FORD MOTOR CO.
Reposition the countershaft in the bearing/oil seal plate.

Fig 13: Installing Countershaft In The Bearing/Oil Seal Plate
Courtesy of FORD MOTOR CO.
Install the first gear needle bearing.

Fig 14: Installing First Gear Needle Bearing
Courtesy of FORD MOTOR CO.
Install the countershaft first gear.

Fig 15: Installing Countershaft First Gear
Courtesy of FORD MOTOR CO.
Assemble the first and second gear synchronizer assembly.

Fig 16: Assembling First And Second Gear Synchronizer Assembly
Courtesy of FORD MOTOR CO.
Install the first and second gear synchronizer assembly.
- Move the synchronizer sliding sleeve to the center position.
  
  Fig 17: Installing First And Second Gear Synchronizer Assembly
  Courtesy of FORD MOTOR CO.
Install the needle bearing inner race and the second gear needle bearing.

Fig 18: Installing Needle Bearing Inner Race
Courtesy of FORD MOTOR CO.
Install the countershaft second gear.

Fig 19: Installing Countershaft Second Gear
Courtesy of FORD MOTOR CO.
Install the countershaft third gear.

Fig 20: Installing Countershaft Third Gear
Courtesy of FORD MOTOR CO.
Install the spacer.

Fig 21: Installing Spacer
Courtesy of FORD MOTOR CO.
Install the countershaft bearing.

Fig 22: Installing Countershaft Bearing
Courtesy of FORD MOTOR CO.

NOTE: The transmission must be in the neutral position before final assembly.

Make sure to position the synchronizer sliding sleeves in the neutral position.