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Output Shaft: Assembly

CAUTION: Immerse the double synchronizer units in a bath of manual transmission fluid before installation.
  1. Carefully clean and check all sliding parts and lubricate them with manual transmission fluid before installation.
    2. NOTE: Do not oil taper roller bearings which are to be used again.
  2. Install the second gear wheel with the double synchronizer and needle roller bearing.
    1. Needle roller bearing
    2. Second gear wheel
    3. Inner synchronizer ring
    4. Synchronizer cone
    5. Outer synchronizer ring
      Fig 1: Installing Second Gear Wheel With Double Synchronizer And Needle Roller Bearing
      G03419700Courtesy of FORD MOTOR CO.
    3. NOTE: Install the synchronizer ring hub with the small collar and the annular groove of the selector ring facing outwards.
    Fig 2: Identifying Synchronizer Assembly Installation Position
    G03419701Courtesy of FORD MOTOR CO.
  3. Installation position of the synchronizer assembly.
    4. NOTE: Installation position see previous step.
  4. Install the first/second gear synchronizer assembly.
    1. Synchronizer assembly
    2. New snap ring
      Fig 3: Installing First/Second Gear Synchronizer Assembly
      G03419702Courtesy of FORD MOTOR CO.
    5. NOTE: Installation position see previous step.
  5. Install the double synchronizer together with the first gear wheel.
    1. Outer synchronizer ring
    2. Synchronizer cone
    3. Inner synchronizer ring
    4. First gear wheel
    5. Needle roller bearing
      Fig 4: Installing Double Synchronizer With First Gear Wheel
      G03419703Courtesy of FORD MOTOR CO.
    6. CAUTION: The output pinion can only be installed on the shaft splines in one position.
    NOTE: Install the output pinion with the mark facing upwards.
  6. Install the output pinion.
    1. Using a suitable driver, install the output pinion.
    2. Install a new snap ring.
      Fig 5: Installing Output Pinion
      G03419704Courtesy of FORD MOTOR CO.
  7. Install the taper roller bearing on the output shaft.
    • Using a suitable driver, install the bearing.
      Fig 6: Installing Taper Roller Bearing On Output Shaft
      G03419705Courtesy of FORD MOTOR CO.
  8. Install the fifth gear wheel.
    1. Bearing
    2. Fifth gear wheel
    3. Synchronizer ring
      Fig 7: Installing Fifth Gear Wheel
      G03419706Courtesy of FORD MOTOR CO.
    9. NOTE: Install the synchronizer hub with the small collar and the annular groove running round it facing outwards.
    Fig 8: Identifying Synchronizer Assembly Installation Position
    G03419707Courtesy of FORD MOTOR CO.
  9. Installation position of the synchronizer assembly.
  10. Install fifth/reverse gear synchronizer assembly
    1. Synchronizer assembly
    2. New snap ring
      Fig 9: Installing Fifth/Reverse Gear Synchronizer Assembly
      G03419708Courtesy of FORD MOTOR CO.
  11. Install the reverse gear wheel.
    1. Synchronizer ring
    2. Bearing
    3. Reverse gear wheel
      Fig 10: Installing Reverse Gear Wheel
      G03419709Courtesy of FORD MOTOR CO.
  12. Install the taper roller bearing.
    • Using a suitable driver, install the bearing.
      Fig 11: Installing Taper Roller Bearing
      G03419710Courtesy of FORD MOTOR CO.
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