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Output Shaft: Disassembly

WARNING: This page is about a different variant/trim than selected.
    CAUTION: Handle the dual synchronizer parts with care.
    Fig 1: Removing Ball Bearing
    G03854598Courtesy of FORD MOTOR CO.
  1. Remove the ball bearing and the fourth gear wheel.
    1. Remove the small snap-ring.
    2. Install the snap-ring.
    3. Using a standard puller, remove the ball bearing.
    4. Remove the fourth gear wheel together with the synchronizer ring.
  2. Remove third and fourth gear synchronizer unit.
    1. Remove the snap-ring.
    2. Remove the gear synchronizer, the third and fourth gear synchronizer unit and the third gear wheel.
    Fig 2: Removing Third And Fourth Gear Synchronizer Unit
    G03854599Courtesy of FORD MOTOR CO.
  3. Remove the third gear synchronizer ring.
    1. Synchronizer ring.
    2. Gear wheel (third gear)
    Fig 3: Removing Third Gear Synchronizer Ring
    G03854600Courtesy of FORD MOTOR CO.
    4. NOTE: The dual synchronizer as shown is used in case off servicing.
    Fig 4: Disassembling Third Gear Synchronizer Unit
    G03854601Courtesy of FORD MOTOR CO.
  4. Disassemble the third gear synchronizer unit.
    1. Outer synchronizer ring
    2. Synchronizer cone
    3. Inner synchronizer ring
    4. Gear wheel (third gear)
  5. Remove the second gear wheel together with the synchronizer unit.
    1. Closed retaining ring
    2. Half-round snap rings
    3. Gear wheel (second gear)
    4. Inner synchronizer ring
    5. Synchronizer cone
    6. Outer synchronizer ring
    Fig 5: Removing Second Gear Wheel Together With Synchronizer Unit
    G03854602Courtesy of FORD MOTOR CO.
    6. NOTE: Remove the synchronizer unit and the first gear wheel together.
    Fig 6: Removing First/Second Gear Synchronizer Together With Reverse Gear Wheel
    G03854603Courtesy of FORD MOTOR CO.
  6. Remove the first gear wheel and the reverse gear wheel together with the gear synchronizer and the synchronizer unit.
    1. Remove the snap-ring.
    2. Remove the first/second gear synchronizer together with the reverse gear wheel.
    3. Outer synchronizer ring
    4. Synchronizer cone
    5. Inner synchronizer ring
    6. Gear wheel (first gear)
    7. CAUTION: Mark the installation position of the selector ring in relation to the gear synchronizer hub.
    Fig 7: Disassembling Synchronizer Hub
    G03854604Courtesy of FORD MOTOR CO.
  7. Disassemble the synchronizer hub.
    1. Selector ring
    2. Synchronizer spring
    3. Synchronizer lock
    4. Gear synchronizer hub
    8. NOTE: Insert a pressure piece into oil the thrower bore.
    Fig 8: Removing Bearing Cone
    G03854605Courtesy of FORD MOTOR CO.
  8. Using the special tools, remove the output shaft bearing cone.
    1. 1. Remove the snap-ring.
      • Position the special tool 307-217 below of the bearing cone.
    2. 3. Remove the bearing cone.
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