Output Shaft: Assembly

WARNING: This page is about a different car, the 2002 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Whenever a bearing has been removed, a new one must be installed.

Fig 1: Pressing On Bearing (First Gear Side)

Courtesy of FORD MOTOR CO.

Using the special tools and a press, press on the bearing (first gear side).

NOTE: When installing the synchronizer blocking ring, align the synchronizer blocking ring groove and synchronizer hub inserts.

Fig 2: Pressing First Gear, Synchronizer Blocking Ring, And Reverse Gear

Courtesy of FORD MOTOR CO.

Using the special tools and a press, press on the first gear, synchronizer blocking ring, and reverse gear.
Install the snap ring.

Fig 3: Installing Snap Ring
Courtesy of FORD MOTOR CO.

NOTE: When installing the synchronizer blocking ring, align the synchronizer blocking ring groove and synchronizer hub inserts.

Fig 4: Pressing On Synchronizer Blocking Ring, Second Gear, And Third Speed Gear

Courtesy of FORD MOTOR CO.

Using the special tools and a press, press on the synchronizer blocking ring, second gear, and third speed gear.
Install the snap ring.

Fig 5: Installing Snap Ring
Courtesy of FORD MOTOR CO.
Using the special tools and a press, press on the fourth speed gear.

Fig 6: Pressing On Fourth Speed Gear
Courtesy of FORD MOTOR CO.
Using the special tools and a press, press on the bearing (fourth gear side).

Fig 7: Pressing On Bearing (Fourth Gear Side)
Courtesy of FORD MOTOR CO.

NOTE: If not within specifications, disassemble and reassemble the output shaft assembly.

Fig 8: Identifying Clearances

Courtesy of FORD MOTOR CO.

Measure the output shaft clearances.
1. Measure the clearance between first gear and the differential drive gear.
2. Measure the clearance between second gear and third gear.