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Output Shaft: Assembly

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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.
    Fig 1: Installing Output Shaft Bearing Cone
    G03854606Courtesy of FORD MOTOR CO.
  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.
    3. NOTE: Marking of selector ring installation position in relation to gear synchronizer hub.
    Fig 2: Assembling Gear Synchronizer
    G03854607Courtesy of FORD MOTOR CO.
  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.
    4. NOTE: Install a new snap ring.
    Fig 3: Installing First Gear And Reverse Gear Wheel
    G03854608Courtesy of FORD MOTOR CO.
  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
    5. NOTE: Re-assemble synchronizer unit prior to installation.
    NOTE: Install new halfround snap rings.
    Fig 4: Installing Second Gear Wheel
    G03854609Courtesy of FORD MOTOR CO.
  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. Gearwheel (second gear)
    5. Half-round snap-rings
    6. Closed retaining ring
    6. NOTE: The dual synchronizer as shown is used in case of servicing.
    Fig 5: Assembling Third Gear Synchronizer Unit
    G03854610Courtesy 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
    G03854611Courtesy 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 Gear Synchronizer, Third/Fourth Gear Synchronizer Unit And Third Gear Wheel
    G03854612Courtesy 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: Installing Fourth Gear Wheel And Ball Bearing
    G03854613Courtesy 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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