Output Shaft

Special Tools:

Disassembly
1. Remove the fifth/reverse gear shift rail and the gear shifter forks.





2. Remove the third/fourth synchronizer hub retaining ring.





3. CAUTION: Hand-tighten the special tool to prevent damage to the gear.

Install the special tool between the second speed gear and the third speed gear with the flat side of the special tool toward the third speed gear.

4. CAUTION: Support the output shaft while using the press to prevent damage if dropped.

Using the special tools, remove the third/fourth synchronizer, the third speed synchronizer blocking ring and third gear as an assembly.





5. Remove the bearing and the third speed gear bearing spacer.





6. CAUTION: Hand-tighten the special tool to prevent damage to the gear.

Remove the fifth speed gear and the first speed gear.
^ Position the special tool with the flat side of the special tool toward the fifth speed gear.
^ Using the special tools, remove the fifth speed gear, the tapered roller bearing and the first speed gear.
^ Discard the tapered roller bearing.

7. Remove the first speed gear needle bearings.








8. Remove the first/second synchronizer retaining ring.





9. Remove the first/second synchronizer thrust washer, the inner synchronizer cone, synchronizer middle blocking ring and the outer blocker ring.








10. CAUTION: To prevent damage, do not press on the output shaft thrust Range.

Remove the first/second synchronizer hub.
^ Position the special tool behind the second gear.
^ Using the special tools, remove the first/second synchronizer hub and the second gear.








11. Note: Identify the parts for reassembly.

Remove the first/second synchronizer assembly, the second gear and the needle bearings.





12. Using the special tools, remove the input shaft pocket support bearing.

Assembly





1. CAUTION: To prevent damage, do not support the output shaft by the thrust flange.

Using the special tools, install the input shaft support bearing.





2. Lubricate the second speed needle bearing with petroleum jelly and install the bearing.





3. Install the second speed gear.





4. Install the thrust washer.





5. Align the first and second gear synchronizer inner cone with the thrust washer. Install the inner cone.





6. Install the second gear middle blocker ring.
^ Soak the blocker ring in Motorcraft MARCON(R) Multi-Purpose(ATF) Transmission Fluid XT-2-QDX or equivalent for ten minutes.
^ Align the taps on the blocker ring with the pockets on the second gear.
^ Install the blocker ring over the first and second gear synchronizer inner cone.





7. Install the second gear outer blocker ring over the middle blocker ring.





8. Install the first/second synchronizer onto the output drive shaft. The groove on the sleeve must face towards the front of the output shaft.





9. Note: Make sure the insert on the synchronizer aligns with the pockets on the outer blocker ring.

Using the special tools, install the first/second synchronizer.





10. Install the first speed outer blocker ring.
^ Soak the blocker ring in Motorcraft MARCON(R) Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or equivalent for ten minutes.
^ Align the triangular marker on the outer blocker ring with the arrow on the synchronizer.
^ Install the first speed outer blocker ring.





11. Install the first speed middle blocker ring.
^ Soak the blocker ring in Motorcraft MERCON(R) Multi-Purpose(ATF) Transmission Fluid XT-2-QDX or equivalent for ten minutes.
^ The tab on the blocking ring must face up.
^ Install the first speed middle blocker ring.





12. Install the first and second gear inner cone.





13. Install the first and second speed synchronizer thrust washer.





14. Install the first speed retaining ring with the bevel at the gap facing the synchronizer hub.





15. Lubricate the first speed needle bearings with petroleum jelly. Install the needle bearing.





16. Align the pockets on the first gear with the tabs of the first speed middle blocking ring. Install the first gear.





17. Using the special tools, install a new tapered roller bearing.





18. Position the fifth speed gear with the chamfer facing the tapered roller bearing. Using the special tools, install the fifth speed gear.





19. Install the third speed gear bearing spacer and the bearing.





20. Install the third speed gear.





21. Install the synchronizer blocking ring.
^ Soak the blocker ring in Motorcraft MERCON(R) Multi-Purpose(ATF) Transmission Fluid XT-2-QDX or equivalent for ten minutes.
^ Install the blocking ring.





22. CAUTION: The third/fourth synchronizer struts must index with the pockets in the third speed blocker ring assembly during installation to prevent damage.

Position the third/fourth synchronizer with the groove facing up. Using the special tools, install the synchronizer.





23. Position the third/fourth synchronizer retaining ring with the gap bevel facing the synchronizer. Install the third/fourth synchronizer retaining ring.