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Home >> Ford >> 2000 >> Excursion 7.3 F, 4WD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1375 (Manual Transaxle) >> Disassembly And Assembly Of Subassemblies >> Output Shaft >> Assembly
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Output Shaft: Assembly

WARNING: This page is about a different car, the 2010 Mercury Milan and 2010 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
  1. Lubricate all output shaft components with the recommended transmission lubricant during reassemble.
    NOTE: Do not reassemble the output shaft dry. Apply lubricant throughout the assembly procedure.
  2. Using the Bearing/Oil Seal Plate, Transaxle Bearing Cup Installer and a suitable press, press on a new bearing.
    Fig 1: Pressing Bearing
    G06275990Courtesy of FORD MOTOR CO.
  3. If installing a new output shaft, using a suitable press, install the new spacer.
  4. Install the friction dampener.
  5. 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 Components
    G06182215Courtesy of FORD MOTOR CO.
  6. Assemble the 1st gear blocking ring set and synchronizer.
  7. Using the Bearing/Oil Seal Plate, Differential Bearing Cup Installer and a suitable press, press on the 1st gear, the synchronizer blocking ring and synchronizer assembly.
    NOTE: When installing the synchronizer blocking ring, align the synchronizer blocking ring groove and synchronizer hub inserts to prevent damage.
    Fig 3: Locating 1st Gear, Synchronizer Blocking Ring & Synchronizer Assembly
    G06275992Courtesy of FORD MOTOR CO.
  8. Invert the shaft.
  9. Install a new snap ring.
    Fig 4: Locating Snap Ring
    G06275993Courtesy of FORD MOTOR CO.
  10. Install the synchronizer blocking ring, the synchronizer outer cone and the synchronizer inner cone.
    NOTE: Make sure 1st gear rotates freely.
    Fig 5: Locating Synchronizer Blocking Ring, Synchronizer Outer & Inner Cone
    G06275994Courtesy of FORD MOTOR CO.
  11. Install the friction damper cone onto 2nd gear.
  12. Install 2nd gear.
    Fig 6: Locating 2nd Gear
    G06275995Courtesy of FORD MOTOR CO.
  13. Using a suitable tool, press on 3rd gear.
    • Make sure the slots on 3rd gear are aligned with the fingers on the friction damper cone.
    Fig 7: Locating 3rd Gear
    G06275996Courtesy of FORD MOTOR CO.
  14. Install a new snap ring.
    NOTE: Make sure 2nd gear rotates freely.
    Fig 8: Locating Snap Ring
    G06275997Courtesy of FORD MOTOR CO.
  15. Using a suitable tool, press on 4th gear.
    Fig 9: Locating 4th Gear
    G06275998Courtesy of FORD MOTOR CO.
  16. Invert the output shaft in the press. Using a suitable tool, install a new bearing.
    NOTE: Only press on the inner race of the bearing or damage may occur to the bearing.
  17. 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 (0.001-0.012 in).
    2. Measure the clearance between 2nd gear and 3rd gear. Second gear endplay is 0.18-0.51 mm (0.007-0.02 in).
    NOTE: If not within specifications, disassemble and reassemble the output shaft assembly.
    Fig 10: Identifying Output Shaft Clearances
    G06275999Courtesy of FORD MOTOR CO.
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