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Output (Secondary) Shaft: Reassembly

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  1. To assemble 1st and 2nd gear assembly, install 2nd gear needle bearing, 2nd gear, and 2nd synchronizer blocking ring. Install 1st-2nd synchronizer with identification hole in sleeve facing 2nd gear. Install 1st gear synchronizer blocking ring, 1st gear, and 1st gear needle bearing. Install output bearing spacer. Position output shaft center bearing. See Figure.
  2. Use pinion bearing cone replacer tool, bearing cone replacer, axle bearing/seal plate, and arbor press to press center bearing fully into place on output shaft.
  3. Install 3rd gear bearing, 3rd gear, and 3rd gear synchronizer blocking ring. Then install 3rd-4th synchronizer with chamfer on sleeve facing 4th gear. Install thrust bearing, 3rd-4th synchronizer spacer, bearing outer snap ring, and transmission input shaft pilot bearing.
  4. Check 3rd-4th clutch hub end play. If clearance is not 0.0-0.002" (0.0-0.05 mm) select correct size bearing outer snap ring. Snap rings are available in sizes from 0.0590" (1.50 mm) to 0.0767" (1.95 mm) in increments of 0.002" (0.05 mm). See Fig 1.
    Fig 1: Checking 3rd-4th Clutch Hub End Play
    G98A03310Courtesy of FORD MOTOR CO.
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