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Output Shaft: Assembly

    NOTE: Do not reassemble the output shaft dry. Apply lubricant throughout the assembly procedure.
  1. Lubricate all output shaft components with the recommended transmission lubricant during reassemble.
  2. Using the Bearing/Oil Seal Plate, Transaxle Bearing Cup Installer and a suitable press, press on a new bearing.
    Fig 1: Pressing Bearing Using Bearing/Oil Seal Plate, Transaxle Bearing Cup Installer And Suitable Press
    G07786670Courtesy 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
    G07786671Courtesy of FORD MOTOR CO.
  6. Assemble the 1st gear blocking ring set and synchronizer.
    7. NOTE: When installing the synchronizer blocking ring, align the synchronizer blocking ring groove and synchronizer hub inserts to prevent damage.
    Fig 3: Pressing 1st Gear, Synchronizer Blocking Ring And Synchronizer Assembly Using Bearing/Oil Seal Plate
    G07786672Courtesy of FORD MOTOR CO.
  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.
  8. Invert the shaft.
  9. Install a new snap ring.
    Fig 4: Locating Snap Ring
    G07786673Courtesy of FORD MOTOR CO.
    10. NOTE: Make sure 1st gear rotates freely.
    Fig 5: Locating Synchronizer Blocking Ring, Synchronizer Outer Cone And Synchronizer Inner Cone
    G07786674Courtesy of FORD MOTOR CO.
  10. Install the synchronizer blocking ring, the synchronizer outer cone and the synchronizer inner cone.
  11. Install the friction damper cone onto 2nd gear.
  12. Install 2nd gear.
    Fig 6: Locating 2nd Gear
    G07786675Courtesy 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: Pressing 3rd Gear
    G07786676Courtesy of FORD MOTOR CO.
    14. NOTE: Make sure 2nd gear rotates freely.
    Fig 8: Locating Snap Ring
    G07786677Courtesy of FORD MOTOR CO.
  14. Install a new snap ring.
  15. Using a suitable tool, press on 4th gear.
    Fig 9: Pressing On 4th Gear
    G07786678Courtesy of FORD MOTOR CO.
    16. NOTE: Only press on the inner race of the bearing or damage may occur to the bearing.
  16. Invert the output shaft in the press. Using a suitable tool, install a new bearing.
    17. NOTE: If not within specifications, disassemble and reassemble the output shaft assembly.
    Fig 10: Identifying Differential Drive Gear, First And Second Gear
    G07786679Courtesy of FORD MOTOR CO.
  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).
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