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Output Shaft: Disassembly

Fig 1: Exploded View Of Output Shaft
G01372471Courtesy of FORD MOTOR CO.
CAUTION: When pressing off components, hold the shaft so that it does not fall.
  1. Measure the output shaft clearances.
    1. Measure the clearance between first gear and the differential drive gear.
    2. Measure the clearance between second gear and secondary third gear.
    Fig 2: Measuring Output Shaft Clearances
    G01372472Courtesy of FORD MOTOR CO.
  2. Use an (A) arbor press, (B) Shaft Protector, and (C) Bearing Pulling Attachment to press off the (D) bearing (fourth gear end).
    Fig 3: Pressing Off Bearing - Fourth Gear End
    G01372473Courtesy of FORD MOTOR CO.
  3. Use an (A) arbor press, (B) Shaft Protector, and (C) Bearing Pulling Attachment to press off the (D) fourth speed gear.
    Fig 4: Pressing Off Fourth Speed Gear
    G01372474Courtesy of FORD MOTOR CO.
  4. Remove the snap ring.
    Fig 5: Removing Snap Ring
    G01372475Courtesy of FORD MOTOR CO.
  5. 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 6: Pressing Off Third Speed Gear And Second Gear
    G01372476Courtesy of FORD MOTOR CO.
    6. CAUTION: The synchronizer blocking rings are not interchangeable. Be sure to keep them in the order that they were removed.
    Fig 7: Removing Synchronizer Blocking Ring
    G01372477Courtesy of FORD MOTOR CO.
  6. Remove the synchronizer blocking ring.
  7. Remove the snap ring.
    Fig 8: Removing Snap Ring
    G01372478Courtesy of FORD MOTOR CO.
    8. 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 9: Pressing Off Synchronizer Hub, Synchronizer Blocking Ring, And First Gear
    G01372479Courtesy of FORD MOTOR CO.
  8. 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.
  9. Use (A) Shaft Protector and (B) Bearing Pulling Attachment to press off the (C) bearing (first gear end).
    Fig 10: Pressing Off Bearing - First Gear End
    G01372480Courtesy of FORD MOTOR CO.
  10. Use Dial Indicator/Magnetic Base to measure output shaft gear runout.
    • Inspect the output shaft for worn or damaged gears.
    • Inspect the output shaft for clogged oil passage.
    Fig 11: Measuring Output Shaft Gear Runout
    G01372481Courtesy of FORD MOTOR CO.
    11. NOTE: Set the synchronizer ring squarely in the gear, then measure around the circumference.
    Fig 12: Inspecting Synchronizer Blocking Ring
    G01372482Courtesy of FORD MOTOR CO.
  11. Inspect the synchronizer blocking ring.
    • Measure the clearance from the side of the gear.
    • Inspect for smooth engagement with the gear.
    • Inspect for worn or damaged teeth or tapered surface.
  12. 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.
  13. Measure the clearance between the first/second synchronizer hub and its shift fork.
    Fig 13: Measuring Clearance Between First/Second Synchronizer Hub And Shift Fork
    G01372483Courtesy of FORD MOTOR CO.
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