Output Shaft: Disassembly

WARNING: This page is about a different variant/trim than selected.

CAUTION: Handle the dual synchronizer parts with care.

Remove the ball bearing and the fourth gear wheel.
1. Remove the small snap-ring.
2. Install the snap-ring.
3. Using a standard puller, remove the ball bearing.
4. Remove the fourth gear wheel together with the synchronizer ring.
  
  Fig 1: Removing Ball Bearing And Fourth Gear Wheel
  Courtesy of FORD MOTOR CO.
Remove third and fourth gear synchronizer unit.
1. Remove the snap-ring.
2. Remove the gear synchronizer, the third and fourth gear synchronizer unit and the third gear wheel.
  
  Fig 2: Removing Third And Fourth Gear Synchronizer Unit
  Courtesy of FORD MOTOR CO.
Remove the third gear synchronizer ring.
1. Synchronizer ring.
2. Gear wheel (third gear)
  
  Fig 3: Removing Third Gear Synchronizer Ring
  Courtesy of FORD MOTOR CO.

NOTE: The dual synchronizer as shown is used in case off servicing.

Disassemble the third gear synchronizer unit.
1. Outer synchronizer ring
2. Synchronizer cone
3. Inner synchronizer ring
4. Gear wheel (third gear)
  
  Fig 4: Disassembling Third Gear Synchronizer Unit
  Courtesy of FORD MOTOR CO.
Remove the second gear wheel together with the synchronizer unit.
1. Closed retaining ring
2. Half-round snap rings
3. Gear wheel (second gear)
4. Inner synchronizer ring
5. Synchronizer cone
6. Outer synchronizer ring
  
  Fig 5: Removing Second Gear Wheel Together With Synchronizer Unit
  Courtesy of FORD MOTOR CO.

NOTE: Remove the synchronizer unit and the first gear wheel together.

Remove the first gear wheel and the reverse gear wheel together with the gear synchronizer and the synchronizer unit.
1. Remove the snap-ring.
2. Remove the first/second gear synchronizer together with the reverse gear wheel.
3. Outer synchronizer ring
4. Synchronizer cone
5. Inner synchronizer ring
6. Gear wheel (first gear)
  
  Fig 6: Removing First/Second Gear Synchronizer Together With Reverse Gear Wheel
  Courtesy of FORD MOTOR CO.

CAUTION: Mark the installation position of the selector ring in relation to the gear synchronizer hub.

Disassemble the synchronizer hub.
1. Selector ring
2. Synchronizer spring
3. Synchronizer lock
4. Gear synchronizer hub
  
  Fig 7: Disassembling Synchronizer Hub
  Courtesy of FORD MOTOR CO.

NOTE: Insert a pressure piece into oil the thrower bore.

Using the special tools, remove the output shaft bearing cone.
1. Remove the snap-ring.
  - Position the special tool 307-217 below of the bearing cone.
2. Remove the bearing cone.
  
  Fig 8: Removing Output Shaft Bearing Cone
  Courtesy of FORD MOTOR CO.