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Output Shaft: Assembly

WARNING: This page is about a different variant/trim than selected.
  1. Lubricate all components with the recommended transmission fluid when reassembling.
  2. Using the Bearing Puller, Output Shaft Rear Bearing Installer and the Handle, press the new output shaft front bearing on the output shaft.
    Fig 1: Pressing Output Shaft Front Bearing On Output Shaft Using Special Tools
    G07488993Courtesy of FORD MOTOR CO.
  3. Install the 3rd gear bearing and the spacer.
    • Apply petroleum jelly to the bearing.
    Fig 2: Locating 3rd Gear Bearing And Spacer
    G07488994Courtesy of FORD MOTOR CO.
    4. NOTE: If there is no groove present on the synchronizer body, orientation does not matter.
    Fig 3: Installing 3rd Gear, 3rd Gear Synchronizer Double Cones And 3rd/4th Gear Synchronizer Assembly Using Special Tool
    G07488995Courtesy of FORD MOTOR CO.
  4. Install 3rd gear, the 3rd gear synchronizer double cones and the 3rd/4th gear synchronizer assembly. Position the output shaft with the output end facing upward. Using the Bearing Puller, press the 3rd/4th gear synchronizer assembly into place.
    • Install the synchronizer body with the groove facing 3rd gear.
    • Stop press operation before keys engage the blocking ring slots. Lift and rotate the 3rd gear and the blocking ring until the keys are seated in the blocking ring.
  5. Install a new snap ring.
  6. Install the 2nd gear needle bearing.
    • Apply petroleum jelly to the bearing.
    Fig 4: Locating 2nd Gear Needle Bearing
    G07488996Courtesy of FORD MOTOR CO.
  7. Install 2nd gear and the bearing spacer.
    8. Fig 5: Locating 2nd Gear Needle Bearing And Spacer
    G07488997Courtesy of FORD MOTOR CO.
  8. Install the 2nd gear, the inner cone, the intermediate cone and the 2nd gear synchronizer blocking ring.
    • Align the blocking ring tabs with the 2nd gear slots.
    Fig 6: Locating 2nd Gear
    G07488998Courtesy of FORD MOTOR CO.
    Fig 7: View Of Synchronizer Hub Inner Cone And Outer Cone
    G07488999Courtesy of FORD MOTOR CO.
  9. Install the 1st/2nd gear synchronizer hub assembly into place.
    • Install the synchronizer with the groove on the sleeve facing 1st gear.
    • Lift and rotate the 2nd gear and the blocking ring until the keys are seated in the blocking ring.
  10. Install the split washer.
    Fig 8: Locating Split Washer
    G07489000Courtesy of FORD MOTOR CO.
  11. Install the 1st gear synchronizer sleeve and 3 synchronizer keys.
    Fig 9: View Of Synchronizer Sleeve And Synchronizer Keys
    G07489001Courtesy of FORD MOTOR CO.
  12. Install the 1st gear synchronizer inner cone, the intermediate cone and the 1st gear synchronizer blocking ring.
    Fig 10: View Of 1st Gear Synchronizer Inner Cone And Outer Cone
    G07489002Courtesy of FORD MOTOR CO.
  13. Install the 1st gear needle bearing.
    • Apply petroleum jelly to the bearing.
    Fig 11: Locating 1st Gear Needle Bearing
    G07489003Courtesy of FORD MOTOR CO.
  14. Install 1st gear.
    • Rotate the gear to align the gear slots with the intermediate cone tabs.
  15. Using the Bearing Tube Remover/Installer, install a new rear output shaft bearing.
    Fig 12: Installing Rear Output Shaft Bearing Using Special Tool
    G07489004Courtesy of FORD MOTOR CO.
  16. Using the Bearing Tube Remover/Installer, install the 6th driven gear.
    Fig 13: Installing 6th Driven Gear Using Special Tool
    G07489005Courtesy of FORD MOTOR CO.
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