Output Shaft: Disassembly

CAUTION: The inner synchronizer ring and the synchronizer cone must be handled very carefully.

CAUTION: Only loosely attach the special tool to avoid damaging the synchronizer ring.

Fig 1: Removing Output Shaft Bearing And Reverse Gear

Courtesy of FORD MOTOR CO.

Using a suitable press and the special tool, remove the output shaft bearing and the reverse gear. Discard the output shaft bearing.
Remove the reverse gear needle bearing and the synchronizer ring.

Fig 2: Removing Reverse Gear Needle Bearing And Synchronizer Ring
Courtesy of FORD MOTOR CO.
Remove the fifth/reverse gear synchronizer assembly.
- Remove and discard the snap ring, and remove the synchronizer assembly.
  
  Fig 3: Removing Fifth/Reverse Gear Synchronizer Assembly
  Courtesy of FORD MOTOR CO.
Remove the synchronizer ring, fifth gear and fifth gear needle bearing.

Fig 4: Removing Synchronizer Ring, Fifth Gear And Fifth Gear Needle Bearing
Courtesy of FORD MOTOR CO.

NOTE: Position the special tool with the flat side upward.

Fig 5: Removing Fourth Gear

Courtesy of FORD MOTOR CO.

Using the special tool, remove and discard the snap ring, then remove the fourth gear.

NOTE: Position the special tool with the flat side upward.

Fig 6: Removing Second And Third Gear

Courtesy of FORD MOTOR CO.

CAUTION: Be extremely careful when handling the inner synchronizer ring and synchronizer cone.

Remove the following:
1. The outer synchronizer ring.
2. The synchronizer cone.
3. The inner synchronizer ring.
4. Second gear.
5. Second gear needle bearing.
  
  Fig 7: Removing Inner Synchronizer Ring And Second Gear Needle Bearing
  Courtesy of FORD MOTOR CO.
Remove and discard the snap ring, then remove the first and the second gear synchronizer hub assembly.

Fig 8: Removing First And Second Gear Synchronizer Hub Assembly
Courtesy of FORD MOTOR CO.

CAUTION: Be extremely careful when handling the inner synchronizer ring and synchronizer cone.

Remove the following:
1. The outer synchronizer ring.
2. The inner synchronizer ring.
3. The synchronizer cone.
4. First gear.
5. First gear needle bearing.
  
  Fig 9: Removing Inner Synchronizer Ring And First Gear Needle Bearing
  Courtesy of FORD MOTOR CO.
Using the special tool, remove the clutch housing roller bearing.

Fig 10: Removing Clutch Housing Roller Bearing
Courtesy of FORD MOTOR CO.

NOTE: Mark the installed position of the selector ring.

Disassemble the first/second and fifth/reverse synchronizer hub assemblies. Remove the selector ring from the synchronizer hub. Remove the compression springs, the keys and the detent balls.
- Take care when pulling the selector ring from the synchronizer hub. The detent balls are spring-loaded.
  
  Fig 11: Pulling Selector Ring From Synchronizer Hub
  Courtesy of FORD MOTOR CO.
Inspect the synchronizer assemblies.
- Check for worn, nicked or broken teeth. Install a new synchronizer as necessary.
- Check keys for wear or distortion. Install a new synchronizer as necessary.
- Check springs for distortion. Install a new synchronizer as necessary.