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Output Shaft: Assembly

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    CAUTION: Handle the inner synchronizer ring and the synchronizer cone with extreme care.
    NOTE: Do not lubricate new roller bearings.
  1. Carefully clean and check all sliding parts and lubricate them with manual transmission fluid before assembly.
    2. CAUTION: Handle the inner synchronizer ring and synchronizer cone very carefully.
  2. Install the first gear wheel.
    1. Install the needle roller bearing.
    2. Install the first gear wheel.
    3. Install the inner synchronizer ring.
    4. Install the synchronizer cone.
    5. Install the outer synchronizer ring.
      Fig 1: Installing First Gear Wheel
      G01613546Courtesy of FORD MOTOR CO.
    3. NOTE: Observe the markings.
  3. Assemble the synchronizer hub assembly.
    1. Install the compression springs.
    2. Install the blocker bar and the detent balls in the gear synchronizer hub against the force of the spring.
    3. Install the spring ring the correct way round and push it on.
      Fig 2: Assembling Synchronizer Hub Assembly
      G01613547Courtesy of FORD MOTOR CO.
    4. NOTE: Install the synchronizer hub assembly with the larger collar facing outward (toward the second gear wheel).
    NOTE: Install a new snap ring.
  4. Install the first and the second gear synchronizer hub assembly.
    1. Install the synchronizer hub assembly.
    2. Install the snap ring.
      Fig 3: Installing First And Second Gear Synchronizer Hub Assembly
      G01613548Courtesy of FORD MOTOR CO.
  5. Install the second gear wheel.
    1. Install the needle roller bearing.
    2. Install the outer synchronizer ring.
    3. Install the synchronizer cone.
    4. Install the inner synchronizer ring.
    5. Install the second gear wheel.
      Fig 4: Installing Second Gear Wheel
      G01613549Courtesy of FORD MOTOR CO.
  6. Using the special tool, install the third gear wheel.
    Fig 5: Installing Third Gear Wheel
    G01613550Courtesy of FORD MOTOR CO.
    7. NOTE: Install a new snap ring.
    Fig 6: Installing Fourth Gear Wheel
    G01613551Courtesy of FORD MOTOR CO.
  7. Using the special tool, install the fourth gear wheel.
  8. Install the fifth gear wheel.
    1. Install the needle roller bearing.
    2. Install the fifth gear wheel.
    3. Install the synchronizer ring.
      Fig 7: Installing Fifth Gear Wheel
      G01613552Courtesy of FORD MOTOR CO.
    9. NOTE: Install the synchronizer hub assembly with the small collar and the ring groove facing outward.
    NOTE: Install a new snap ring.
  9. Install the fifth and the reverse gear synchronizer assembly.
    1. Install the synchronizer hub assembly.
    2. Install the snap ring.
      Fig 8: Installing Fifth And Reverse Gear Synchronizer Assembly
      G01613553Courtesy of FORD MOTOR CO.
  10. Install the reverse gear wheel.
    1. Install the synchronizer ring.
    2. Install the needle roller bearing.
    3. Install the reverse gear wheel.
      Fig 9: Installing Reverse Gear Wheel
      G01613554Courtesy of FORD MOTOR CO.
  11. Using a length of a suitable tube, install the transaxle housing roller bearing.
    Fig 10: Installing Transaxle Housing Roller Bearing
    G01613555Courtesy of FORD MOTOR CO.
  12. Using a length of a suitable tube, install a new clutch housing roller bearing.
    Fig 11: Installing New Clutch Housing Roller Bearing
    G01613556Courtesy of FORD MOTOR CO.
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