Output Shaft: Assembly

NOTE: Do not lubricate new roller bearings.

Lubricate all transmission components with transmission fluid during reassembly.

NOTE: Handle the inner synchronizer ring and synchronizer cone very carefully.

Install the following:
1. First gear needle bearing
2. First gear
3. Inner synchronizer ring
4. Synchronizer cone
5. Outer synchronizer ring

Fig 1: Identifying Inner And Outer Synchronizer Ring And Cone

Courtesy of FORD MOTOR CO.

NOTE: Observe the markings on the selector ring.

NOTE: Place a rubber band around the synchronizer body. Install the springs, the synchronizer bars and detent balls. Slide the synchronizer sleeve over the synchronizer body, while moving the rubber band downward.

Assemble the synchronizer hub assembly.
1. Install the compression springs.
2. Install the keys and the detent balls in the gear synchronizer hub against the force of the spring.
3. Align the selector ring with the hub and push it on.

Fig 2: Identifying Compression Springs And Selector Ring

Courtesy of FORD MOTOR CO.

NOTE: Install the synchronizer hub assembly with the larger collar facing toward 2nd gear.

Install the 1st/2nd gear synchronizer hub assembly, then install a new snap ring.

Fig 3: Locating 1st/2nd Gear Synchronizer Hub And Snap Ring

Courtesy of FORD MOTOR CO.

Install the following:
1. Second gear needle bearing
2. Outer synchronizer ring
3. Synchronizer cone
4. Inner synchronizer ring
5. Second gear

Fig 4: Identifying 2nd Gear Needle Bearing And Cone

Courtesy of FORD MOTOR CO.

Using a press and the special tool, install 3rd gear.

Fig 5: Installing 3rd Gear

Courtesy of FORD MOTOR CO.

Using a press and the special tool, install 4th gear. Install a new snap ring.

Fig 6: Installing 4th Gear And Snap Ring

Courtesy of FORD MOTOR CO.

Install the 5th gear needle bearing, 5th gear and the synchronizer ring.

Fig 7: Installing 5th Gear Needle Bearing, 5th Gear And Synchronizer Ring

Courtesy of FORD MOTOR CO.

NOTE: Install the synchronizer hub assembly with the small collar and the ring groove facing outward.

Install the 5th/reverse gear synchronizer assembly and a new snap ring.

Fig 8: Installing 5th/Reverse Gear Synchronizer Assembly

Courtesy of FORD MOTOR CO.

Install the synchronizer ring, the reverse gear needle bearing and the reverse gear.

Fig 9: Locating Synchronizer Ring, Reverse Gear Needle Bearing And Reverse Gear

Courtesy of FORD MOTOR CO.

Using a suitable step plate and a press, press the bearing on by the inner race only. Install a new output shaft bearing.

Fig 10: Installing Output Shaft Bearing

Courtesy of FORD MOTOR CO.

Using a suitable step plate and a press, press the bearing on by the inner race only. Install a new output shaft bearing.

Fig 11: Installing Output Shaft Bearing

Courtesy of FORD MOTOR CO.