Output Shaft: Assembly

WARNING: This page is about a different car, the 2006 Mercury Milan and 2006 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: Do not reassemble the output shaft dry. Apply lubricant throughout the assembly procedure.

Lubricate all output shaft components with the recommended transmission lubricant during reassemble.
Using the special tools, press on a new bearing.

Fig 1: Identifying Special Tools And New Bearing
Courtesy of FORD MOTOR CO.
Assemble the synchronizer.
1. Position the synchronizer hub to the sleeve.
2. Install the hub inserts.
3. Install the blocking spring.
4. Rotate the synchronizer and install the opposite blocking spring.
  
  Fig 2: Identifying Synchronizer Hub Assembly
  Courtesy of FORD MOTOR CO.

NOTE: When installing the synchronizer blocking ring, align the synchronizer blocking ring groove and synchronizer hub inserts.

Fig 3: Locating Special Tools, 1St Gear, Synchronizer Blocking Ring And Reverse Gear

Courtesy of FORD MOTOR CO.

Using the special tools, press on the 1st gear, the synchronizer blocking ring and reverse gear.
Install a new snap ring.

Fig 4: Locating Snap Ring
Courtesy of FORD MOTOR CO.
Install the synchronizer blocking ring, the synchronizer outer cone and the synchronizer inner cone.

Fig 5: Locating Synchronizer Blocking Ring, Synchronizer Outer Cone And Synchronizer Inner Cone
Courtesy of FORD MOTOR CO.
Install 2nd gear.

Fig 6: Locating 2Nd Gear
Courtesy of FORD MOTOR CO.
Install the friction damper cone.

Fig 7: Locating Friction Damper Cone
Courtesy of FORD MOTOR CO.
Using a suitable driver, press on 3rd gear.
- Make sure the slots on 3rd gear are aligned with the fingers on the friction damper cone.
  
  Fig 8: Locating 3Rd Gear
  Courtesy of FORD MOTOR CO.
Install a new snap ring.

Fig 9: Locating Snap Ring
Courtesy of FORD MOTOR CO.
Using a suitable driver, press on 4th gear.

Fig 10: Locating 4Th Gear
Courtesy of FORD MOTOR CO.
Rotate the output shaft in the press. Using the special tools, install a new bearing.

NOTE: If not within specifications, disassemble and reassemble the output shaft assembly.

Measure the output shaft clearances.
1. Measure the clearance between 1st gear and the differential drive gear.
2. Measure the clearance between 2nd gear and 3rd gear.
  
  Fig 11: Identifying 1St Gear And Differential Drive Gear And Clearance Between 2Nd Gear And 3Rd Gear
  Courtesy of FORD MOTOR CO.