Output Shaft: Disassembly

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

Measure the output shaft clearances.
1. Measure the clearance between first gear and the differential drive gear.
  
  Fig 1: Measuring Output Shaft Clearances
  Courtesy of FORD MOTOR CO.
2. Measure the clearance between second gear and secondary third gear.
Use an (A) arbor press, (B) Shaft Protector, and (C) Bearing Pulling Attachment to press off the (D) bearing (fourth gear end).

Fig 2: Pressing Bearing (Fourth Gear End)
Courtesy of FORD MOTOR CO.
Use an (A) arbor press, (B) Shaft Protector, and (C) Bearing Pulling Attachment to press off the (D) fourth speed gear.

Fig 3: Pressing Fourth Speed Gear
Courtesy of FORD MOTOR CO.
Remove the snap ring.

Fig 4: Removing Snap Ring
Courtesy of FORD MOTOR CO.
Use an (A) arbor press, (B) Shaft Protector, and (C) Bearing Pulling Attachment to press off the (D) third speed gear and (E) second gear.

Fig 5: Pressing Third Speed Gear And Second 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 6: Removing Synchronizer Blocking Ring

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.

NOTE: Inspect all the synchronizer components for wear and damage; refer to SYNCHRONIZERS .

Fig 8: Pressing Synchronizer Hub, Synchronizer Blocking Ring, And First Gear

Courtesy of FORD MOTOR CO.

Use an (A) arbor press, (B) Shaft Protector, and (C) press blocks to press off the (D) synchronizer hub, (E) synchronizer blocking ring, and (F) first gear.
Use (A) Shaft Protector and (B) Bearing Pulling Attachment to press off the (C) bearing (first gear end).

Fig 9: Pressing Bearing (First Gear End)
Courtesy of FORD MOTOR CO.
Use Dial Indicator/Magnetic Base to measure output shaft gear runout.
- Inspect the output shaft for worn or damaged gears.
  
  Fig 10: Measuring Output Shaft Gear Runout
  Courtesy of FORD MOTOR CO.
- Inspect the output shaft for clogged oil passage.

NOTE: Set the synchronizer ring squarely in the gear, then measure around the circumference.

Inspect the synchronizer blocking ring.
- Measure the clearance from the side of the gear.
  
  Fig 11: Measuring Clearance From Side Of Gear
  Courtesy of FORD MOTOR CO.
- Inspect for smooth engagement with the gear.
- Inspect for worn or damaged teeth or tapered surface.
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 first/second synchronizer hub and its shift fork.

Fig 12: Measuring Clearance Between First/Second Synchronizer Hub And Shift Fork
Courtesy of FORD MOTOR CO.