Output Shaft: Disassembly

Using the special tool and a press, remove the third/fourth gear synchronizer assembly (7124), the third speed synchronizer blocking ring (7107), and the third gear (7B340) as an assembly.

Fig 1: Removing Third/Fourth Gear Synchronizer Assembly
Courtesy of FORD MOTOR CO.
Remove the third speed bearing (7B369) and the third speed gear bearing spacer (7B320).

Fig 2: Removing Third Speed Bearing And Third Speed Gear Bearing Spacer
Courtesy of FORD MOTOR CO.
Remove the snap ring.

Fig 3: Removing Snap Ring
Courtesy of FORD MOTOR CO.
Using the special tool and a press, remove the fifth speed driven gear (7K316).

Fig 4: Removing Fifth Speed Driven Gear
Courtesy of FORD MOTOR CO.
Remove the output shaft rear bearing (7065).

Fig 5: Removing Output Shaft Rear Bearing
Courtesy of FORD MOTOR CO.
Remove the first gear (7100).

Fig 6: Removing First Gear
Courtesy of FORD MOTOR CO.

NOTE: The first gear bearing spacer (7173) fits snugly on the output shaft assembly (7061).

Fig 7: Removing First Gear Bearing And Spacer

Courtesy of FORD MOTOR CO.

Remove the first gear bearing (7127) and the spacer as an assembly.
Remove the first and second speed synchronizer hub ball (7K218).

Fig 8: Removing First And Second Speed Synchronizer Hub Ball
Courtesy of FORD MOTOR CO.
Remove the first speed synchronizer inner cone (7175), the first speed synchronizer outer cone (7174), and the first speed synchronizer blocking ring (7107) as an assembly.

Fig 9: Removing First Speed Synchronizer Inner Cone
Courtesy of FORD MOTOR CO.
Remove the snap ring and the thrust washer (7119).

Fig 10: Removing Snap Ring And Thrust Washer
Courtesy of FORD MOTOR CO.
Remove the second gear (7102), the second speed bearing (7B369), and the second speed gear bearing spacer (7728).

Fig 11: Removing Second Gear
Courtesy of FORD MOTOR CO.
Remove the output shaft bearing snap ring and the second speed synchronizer thrust washer (7117).

Fig 12: Removing Output Shaft Bearing Snap Ring And Second Speed Synchronizer Thrust Washer
Courtesy of FORD MOTOR CO.
Remove the second speed synchronizer inner cone (7175), the second speed synchronizer outer cone (7174), and the second speed synchronizer blocking ring (7107) as an assembly.

Fig 13: Removing Second Speed Synchronizer Inner And Outer Cone
Courtesy of FORD MOTOR CO.
Remove the first and second gear synchronizer sliding sleeve (7124).

CAUTION: Note the orientation of the synchronizer hub insert springs (7109) and the synchronizer hub inserts (7A044) for assembly reference.

NOTE: The first and second gear synchronizer sliding sleeve, the hub, and the output shaft are an assembly. Do not attempt to separate the hub from the output shaft. Only the synchronizer hub insert springs and the synchronizer hub inserts are available separately.

Fig 14: Removing First And Second Gear Synchronizer Sliding Sleeve

Courtesy of FORD MOTOR CO.

Remove the synchronizer hub insert springs and the hub inserts.