Output Shaft: Disassembly

WARNING: This page is about a different variant/trim than selected.

Fig 1: Disassembled View Of Output Shaft Components

Courtesy of FORD MOTOR CO.

PARTS DESCRIPTION CHART

Item	Part Number	Description
1	7025	Output shaft front bearing
2	7A082	Snap ring
3	7124	3rd/4th synchronizer assembly
4	7107	3rd/4th synchronizer blocking ring assembly
5	-	Synchronizer blocking ring (part of 7107)
6	-	Synchronizer outer cone (part of 7107)
7	-	Synchronizer inner cone (part of 7107)
8	7117	Spacer
9	7B340	3rd gear
10	7025	3rd gear needle bearing
11	7061	Output shaft
12	7102	2nd gear
13	7025	2nd gear needle bearing
14	7117	Spacer
15	7107	2nd gear synchronizer blocking ring assembly
16	-	Synchronizer inner cone (part of 7107)
17	-	Synchronizer outer cone (part of 7107)
18	-	Synchronizer blocking ring (part of 7107)
19	7124	1st/2nd synchronizer assembly
20	7107	1st gear synchronizer blocking ring assembly
21	-	Synchronizer blocking ring (part of 7107)
22	-	Synchronizer outer cone (part of 7107)
23	-	Synchronizer inner cone (part of 7107)
24	7117	Spacer
25	7100	1st gear
26	7025	1st gear needle bearing
27	7025	Output shaft rear bearing
28	7L047	6th driven gear
29	7K316	5th driven gear
30	7A385	Thrust washer
31	-	Split washer
32	-	Synchronizer cone (part of 7107)
33	7124	Reverse synchronizer assembly
34	7A082	Snap ring
35	7107	Reverse gear synchronizer blocking ring assembly
36	-	Synchronizer blocking ring (part of 7107)
37	-	Synchronizer outer cone (part of 7107)
38	-	Synchronizer inner cone (part of 7107)
39	7N168	Reverse gear needle bearing
40	7C238	Reverse gear
41	7A385	Thrust washer
42	7A082	Snap ring
43	-	Spacer
44	7025	Rear output shaft bearing
45	-	Spacer
46	7A082	Snap ring
47	7E172	Check ball
48	7H150	Speedometer rotor
49	7A082	Snap ring
50	-	Spacer
51	-	Output shaft bearing race

Remove the 3rd/4th synchronizer sleeve.

NOTE: Hand-tighten the Bearing Puller to prevent gear damage.

NOTE: Support the output shaft while using the press to prevent damage to the shaft or gears.

Fig 2: Removing 1st Gear, Output Shaft Rear Bearing And 6th Driven Gear Using Special Tool

Courtesy of FORD MOTOR CO.

Using the Bearing Puller and a press, remove 1st gear, the output shaft rear bearing and the 6th driven gear.
- Discard the output shaft bearing.
- Inspect the gears for wear or damage. Install a new gear as necessary.
Remove the 1st gear needle bearing.
- Inspect the needle bearing for wear or damage. Install a new needle bearing as necessary.
Remove the 1st gear synchronizer inner cone, the outer cone and the blocking ring.
- Inspect all components for wear or damage. Install new components as necessary.
Fig 3: View Of 1st Gear Synchronizer Inner Cone And Outer Cone
Courtesy of FORD MOTOR CO.
Remove the synchronizer sleeve and the 3 synchronizer keys.

Fig 4: View Of Synchronizer Sleeve And Synchronizer Keys
Courtesy of FORD MOTOR CO.
Remove the split washer.

Fig 5: Locating Split Washer
Courtesy of FORD MOTOR CO.
Remove the 1st/2nd gear synchronizer hub.
Remove the inner cone, the outer cone, the 2nd gear synchronizer blocking ring and the synchronizer hub.
- Inspect all synchronizer components for wear or damage. Install new components as necessary.
Fig 6: View Of Synchronizer Hub Inner Cone And Outer Cone
Courtesy of FORD MOTOR CO.
Remove 2nd gear.
- Inspect 2nd gear for wear or damage. Install a new gear as necessary.
Fig 7: Locating 2nd Gear
Courtesy of FORD MOTOR CO.
Remove the 2nd gear needle bearing and the spacer.
- Inspect the needle bearing for wear or damage. Install a new needle bearing as necessary.
Fig 8: Locating 2nd Gear Needle Bearing And Spacer
Courtesy of FORD MOTOR CO.

NOTE: Reposition the output shaft on the press with the input shaft end facing upward.

Fig 9: Removing 3rd/4th Gear Synchronizer Assembly, 3rd Gear Synchronizer Double Cone And 3rd Gear Using Special Tool

Courtesy of FORD MOTOR CO.

Remove and discard the snap ring, then using the Bearing Puller, remove the 3rd/4th gear synchronizer assembly, the 3rd gear synchronizer double cone and the 3rd gear.
- Inspect the gear for broken or cracked teeth. Install a new gear as necessary.
- Inspect all synchronizer components for wear or damage. Install new components as necessary.
Remove the 3rd gear needle bearing and the spacer.
- Inspect the needle bearing for wear or damage. Install a new needle bearing as necessary.
Fig 10: Locating 3rd Gear Needle Bearing And Spacer
Courtesy of FORD MOTOR CO.

NOTE: Install the Bearing Puller with the flat side facing the bearing.

Fig 11: Pressing Output Shaft Front Bearing From Output Shaft Using Special Tool

Courtesy of FORD MOTOR CO.

Using the Bearing Puller, press the output shaft front bearing from the output shaft. Discard the bearing.
Inspect the synchronizers.
- Check for worn, nicked or broken teeth. Install a new synchronizer as necessary.
- Check keys for wear or damage. Install a new synchronizer as necessary.
Inspect the synchronizer blocking rings.
- Check for wear or damage. Install new synchronizer blocking rings as necessary.
- Check the clearance between the synchronizer blocking ring and the gear.
- Position the blocking ring onto the gear. Make sure the correct blocking ring is measured with the correct gear and that the blocking ring is fully seated on the gear.
- Insert a feeler gauge and measure the clearance, while applying pressure and rotating the blocking ring. The measurement should be the same around the entire circumference. If the clearance is less than 0.38 mm (0.015 in), install new blocking rings.
Fig 12: Checking Clearance Between Synchronizer Blocking Ring And Gear With Specifications
Courtesy of FORD MOTOR CO.
Inspect the output shaft for scoring or worn or damaged splines. Install a new output shaft as necessary.