Output Shaft: Assembly

Soak the blocking rings in transmission fluid for ten minutes.
- Use MERCON® Multi-Purpose ATF Transmission Fluid XT-2-QDX or equivalent.
Assemble the first and second synchronizer.
1. Install the synchronizer hub insert springs and the synchronizer inserts into the synchronizer hub.
2. Install the sliding sleeve onto the hub.
  
  Fig 1: Assembling First And Second Synchronizer
  Courtesy of FORD MOTOR CO.

NOTE: If not done so previously, soak the blocking ring in MERCON® Multi-Purpose ATF Transmission Fluid XT-2-QDX or equivalent for ten minutes.

NOTE: Align the slots in the synchronizer blocking ring with the tabs in the first and second speed synchronizer.

Fig 2: Installing Second Speed Synchronizer Blocking Ring And Inner And Outer Cones

Courtesy of FORD MOTOR CO.

Install the second speed synchronizer blocking ring and the inner and outer cones as an assembly.
Install the second speed synchronizer thrust washer.
Using the special tool, install the output shaft bearing snap ring.

Fig 3: Installing Output Shaft Bearing Snap Ring
Courtesy of FORD MOTOR CO.
Install the second speed gear bearing spacer and the second speed bearing.

Fig 4: Installing Second Speed Gear Bearing Spacer And Second Speed Bearing
Courtesy of FORD MOTOR CO.

NOTE: Align the slots in the second gear with the tabs on the synchronizer blocking ring.

Fig 5: Installing Second Gear Onto Output Shaft

Courtesy of FORD MOTOR CO.

Install the second gear onto the output shaft.
Install the thrust washer and the snap ring.

Fig 6: Installing Thrust Washer And Snap Ring
Courtesy of FORD MOTOR CO.

NOTE: If not done so previously, soak the blocking ring in MERCON® Multi-Purpose ATF Transmission Fluid XT-2-QDX or equivalent for ten minutes.

NOTE: Align the slot in the synchronizer blocking ring with the tab on the first and second synchronizer.

Fig 7: Installing First Speed Synchronizer Blocking Ring And Inner And Outer Cones

Courtesy of FORD MOTOR CO.

Install the first speed synchronizer blocking ring and the inner and outer cones as an assembly.
Install the first and second speed synchronizer hub ball.

Fig 8: Installing First And Second Speed Synchronizer Hub Ball
Courtesy of FORD MOTOR CO.

NOTE: Align the notch in the first gear bearing spacer with the first and second speed synchronizer ball.

Fig 9: Installing First Gear Bearing Spacer And First Gear Bearing

Courtesy of FORD MOTOR CO.

Install the first gear bearing spacer and the first gear bearing.

NOTE: Align the slots on the synchronizer blocking ring with the slots on the first gear.

Fig 10: Installing First Gear

Courtesy of FORD MOTOR CO.

Install the first gear.
Install the output shaft rear bearing.

Fig 11: Installing Output Shaft Rear Bearing
Courtesy of FORD MOTOR CO.
Lubricate the splines of the fifth speed driven gear with petroleum jelly.

CAUTION: Align the output shaft splines and the splines of the fifth speed driven gear or damage will occur.

Fig 12: Positioning Fifth Speed Driven Gear On Output Shaft

Courtesy of FORD MOTOR CO.

Position the fifth speed driven gear on the output shaft. Using a press and a capped length of pipe 31.7 mm (1.26 in) inside diameter X 356 mm (14.24 in) long, install the fifth speed driven gear.
Install the snap ring.

Fig 13: Installing Snap Ring
Courtesy of FORD MOTOR CO.
Install the third speed gear bearing spacer and the third speed bearing.

Fig 14: Installing Third Speed Gear Bearing Spacer And Third Speed Bearing
Courtesy of FORD MOTOR CO.

CAUTION: Before pressing the components together, verify that the synchronizer hub faces the short end of the output shaft. Hold the third gear against the synchronizer to maintain the synchronizer blocking ring alignment.

NOTE: If not done so previously, soak the blocking ring in MERCON® Multi-Purpose ATF Transmission Fluid XT-2-QDX or equivalent for ten minutes.

Fig 15: Installing Third Gear, Third Speed Synchronizer Blocking Ring

Courtesy of FORD MOTOR CO.

Using a 1-1/2 inch deep well socket and a press, install the third gear, the third speed synchronizer blocking ring, and the third/fourth gear synchronizer assembly.