Output Shaft: Disassembly

CAUTION: When pressing off components, hold the shaft so that it does not fall

Measure the output shaft clearances.
1. Measure the clearance between first gear and the differential drive gear.
2. Measure the clearance between second gear and secondary third gear.
  
  Fig 1: Measuring Output Shaft Clearances
  Courtesy of FORD MOTOR CO.
Using the special tools and press, press off the bearing (fourth gear end).

Fig 2: Pressing Bearing Using SST
Courtesy of FORD MOTOR CO.
Using the special tools and a press, press off the fourth speed gear.

Fig 3: Pressing Fourth Speed Gear Using SST
Courtesy of FORD MOTOR CO.
Remove the snap ring.

Fig 4: Removing Snap Ring
Courtesy of FORD MOTOR CO.
Using the special tools and a press, press off the third speed gear and second gear.

Fig 5: Pressing Third Speed Gear And Second Gear Using SST
Courtesy of FORD MOTOR CO.

CAUTION: The synchronizer blocking rings are not interchangeable. Be sure to keep them in the order that they were removed.

Fig 6: Removing Synchronizer Blocking Ring

Courtesy of FORD MOTOR CO.

CAUTION: The synchronizer blocking rings are not interchangeable. Make sure to keep them in the order that they were removed.

NOTE: Inspect all the synchronizer components for wear and damage; refer to SYNCHRONIZERS - FIRST/SECOND AND THIRD/FOURTH GEARS for Vehicles Built After 3/2002 in this article.

Fig 8: Inspecting Synchronizer Components

Courtesy of FORD MOTOR CO.

Using the special tools and a press, press off the synchronizer hub, synchronizer blocking ring, and first gear.
Using the special tools and a press, press off the bearing (first gear end).

Fig 9: Pressing Bearing (First Gear End) Using SST
Courtesy of FORD MOTOR CO.
Measure output shaft gear runout.
- Inspect the output shaft for worn or damaged gears.
- Inspect the output shaft for clogged oil passage.
  
  Fig 10: Measuring Output Shaft Gear Runout
  Courtesy of FORD MOTOR CO.

NOTE: Set the synchronizer ring squarely in the gear, then measure around the circumference.

Inspect the synchronizer blocking ring.
- Measure the clearance from the side of the gear.
- Inspect for smooth engagement with the gear.
- Inspect for worn or damaged teeth or tapered surface.
  
  Fig 11: Measuring Clearance From Side Of Gear
  Courtesy of FORD MOTOR CO.
Inspect the synchronizer hub.
- Inspect worn or damaged splines, synchronizer insert groove or end surface.
- Inspect for smooth hub sleeve movement when it is installed.
Measure the clearance between the first/second synchronizer hub and its shift fork.

Fig 12: Measuring Clearance Between The First/Second Synchronizer Hub
Courtesy of FORD MOTOR CO.