Output Shaft: Disassembly

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: When pressing off components, hold the shaft so that it does not fall.

Measure the output shaft clearances.
1. Measure the clearance between 1st gear and the differential drive gear. First gear endplay is 0.05-0.33 mm (0.002-0.013 in).
2. Measure the clearance between 2nd gear and secondary 3rd gear. Second gear endplay is 0.18-0.51 mm (0.007-0.20 in).
  
  Fig 1: Identifying Clearance Between 1St Gear And Differential Drive Gear And 2Nd Gear And Secondary 3Rd Gear
  Courtesy of FORD MOTOR CO.
Using the special tools, press off the bearing and 4th gear.
- Discard the bearing.
- Always install new bearings and cups as a set. Do not install one without the other.
  
  Fig 2: Locating Special Tool, Bearing And 4Th Gear
  Courtesy of FORD MOTOR CO.
Remove and discard the snap ring.

Fig 3: Locating Snap Ring
Courtesy of FORD MOTOR CO.
Using the special tools, press off the 3rd gear and 2nd gear.

Fig 4: Locating Special Tools, 3Rd Gear And 2Nd Gear
Courtesy of FORD MOTOR CO.

CAUTION: The synchronizer blocking rings are not interchangeable. Be sure to keep them in the order that they were removed.

Fig 5: Locating Synchronizer Blocking Ring And Special Tool

Courtesy of FORD MOTOR CO.

Remove the synchronizer blocking ring, the synchronizer inner cone and the synchronizer outer cone.
Remove and discard the snap ring.

Fig 6: Locating Snap Ring
Courtesy of FORD MOTOR CO.

CAUTION: The synchronizer blocking rings are not interchangeable. Make sure to keep them in the order that they were removed.

Fig 7: Locating Special Tools, Synchronizer Hub, Synchronizer Blocking Ring And 1St Gear

Courtesy of FORD MOTOR CO.

Using the special tools, press off the synchronizer hub, synchronizer blocking ring and 1st gear.
Disassemble the synchronizer assembly.
1. Remove the synchronizer blocking spring.
2. Rotate the synchronizer and remove the opposite spring.
3. Remove the hub inserts.
4. Separate the synchronizer hub from the sleeve.
  - Inspect all synchronizer components for wear or damage. Install a new synchronizer as necessary.
    
    Fig 8: Separating Synchronizer Assembly
    Courtesy of FORD MOTOR CO.
Using the special tools, press off the bearing.
- Discard the bearing.
- Always install new bearings and cups as a set. Do not install one without the other.
  
  Fig 9: Locating Special Tool And Bearing
  Courtesy of FORD MOTOR CO.
Measure the output shaft gear runout.
- Inspect the output shaft for wear or damage.
- Inspect the output shaft for a clogged oil passage.
- Maximum output shaft gear runout is 0.015 mm (0.0006 in).
- Install an output shaft gear as necessary.
  
  Fig 10: Measuring Output Shaft Gear Runout
  Courtesy of FORD MOTOR CO.
Set the synchronizer ring squarely in the gear, then measure around the circumference.
- Measure the clearance from the side of the gear.
  - Synchronizer ring clearance is 0.80-1.50 mm (0.031-0.059 in).
- Inspect for smooth engagement with the gear.
- Inspect for worn or damaged teeth or tapered surface. Install new components as necessary.
  
  Fig 11: Measuring Synchronizer Ring Clearance
  Courtesy of FORD MOTOR CO.
Inspect the synchronizer hub.
- Inspect for worn or damaged splines, synchronizer insert groove or end surface.
- Inspect for smooth hub sleeve movement when it is installed.
Measure the clearance between the 1st/2nd synchronizer hub and its shift fork.
- Shift fork and hub sleeve clearance is 0.10-0.45 mm (0.004-0.017 in).