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Output Shaft: Disassembly

WARNING: This page is about a different variant/trim than selected.
CAUTION: The inner synchronizer ring and the synchronizer cone must be handled very carefully.
  1. General note
    • If replacement of bearings, shafts or the transaxle housings is necessary, the transaxle must be shimmed.
    2. CAUTION: Only loosely attach the special tool to avoid damaging the synchronizer ring.
    Fig 1: Removing Taper Roller Bearing Together With Reverse Gear Wheel
    G01613535Courtesy of FORD MOTOR CO.
  2. Using the special tool, remove the taper roller bearing together with the reverse gear wheel.
  3. Remove the needle roller bearing and the synchronizer ring.
    1. Remove the needle roller bearing.
    2. Remove the synchronizer ring.
      Fig 2: Removing Needle Roller Bearing And Synchronizer Ring
      G01613536Courtesy of FORD MOTOR CO.
  4. Remove the fifth and reverse gear synchronizer assembly.
    1. Remove the snap ring.
    2. Remove the synchronizer assembly.
    • Discard the snap ring.
      Fig 3: Removing Fifth And Reverse Gear Synchronizer Assembly
      G01613537Courtesy of FORD MOTOR CO.
  5. Remove the fifth gear.
    1. Remove the synchronizer ring.
    2. Remove the fifth gear.
    3. Remove the roller bearing.
      Fig 4: Removing Fifth Gear
      G01613538Courtesy of FORD MOTOR CO.
    6. NOTE: Use the special tool with the flat side upward.
  6. Using the special tool, remove the fourth gear wheel.
    • Discard the snap ring.
      Fig 5: Removing Fourth Gear Wheel
      G01613539Courtesy of FORD MOTOR CO.
    7. NOTE: Use the special tool with the flat side upward.
    Fig 6: Removing Second And Third Gear Wheel
    G01613540Courtesy of FORD MOTOR CO.
  7. Using the special tool, remove the second and the third gear wheel.
    8. CAUTION: Be extremely careful when handling the inner synchronizer ring and synchronizer cone.
  8. Remove the second gear wheel.
    1. Remove the outer synchronizer ring.
    2. Remove the synchronizer cone.
    3. Remove the inner synchronizer ring.
    4. Remove the second gear wheel.
    5. Remove the needle roller bearing.
      Fig 7: Removing Second Gear Wheel
      G01613541Courtesy of FORD MOTOR CO.
  9. Remove the first and the second gear synchronizer hub assembly.
    1. Discard the snap ring.
    2. Remove the synchronizer hub assembly.
      Fig 8: Removing First And Second Gear Synchronizer Hub Assembly
      G01613542Courtesy of FORD MOTOR CO.
    10. CAUTION: Be extremely careful when handling the inner synchronizer ring and synchronizer cone.
  10. Remove the first gear wheel.
    1. Remove the outer synchronizer ring.
    2. Remove the inner synchronizer ring.
    3. Remove the synchronizer cone.
    4. Remove the first gear wheel.
    5. Remove the needle roller bearing.
      Fig 9: Removing First Gear Wheel
      G01613543Courtesy of FORD MOTOR CO.
  11. Using the special tool, remove the clutch housing roller bearing.
    Fig 10: Removing Clutch Housing Roller Bearing
    G01613544Courtesy of FORD MOTOR CO.
    12. CAUTION: Take care when removing the selector ring from the synchronizer hub assembly. The detent balls are spring-loaded.
    NOTE: Mark the installed position of the selector ring.
  12. Disassemble the synchronizer hub assembly.
    1. Remove the shift ring.
    2. Remove the synchronizer hub.
    3. Remove the compression springs.
    4. Remove the blocker bars.
    5. Remove the detent balls.
      Fig 11: Disassembling Synchronizer Hub Assembly
      G01613545Courtesy of FORD MOTOR CO.
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