Output Shaft: Assembly

Carry out the following before reassembling:
- Inspect the gears for broken or cracked teeth. Check for unusual wear patterns.
- Inspect the thrust washers for face wear, cracks, scoring and for signs of heat damage.
- Inspect the bearings, bearing cups and the synchronizers for wear or damage.
- Inspect the output shaft for scoring or worn or damaged splines. Install new components as necessary.
Lubricate all components with the recommended transmission fluid when reassembling.

CAUTION: Make sure the alignment marks are matched correctly before installing the synchronizer on the shaft.

NOTE: Position the output shaft with the output end facing upward.

Install the first/second synchronizer assembly on the output shaft, then install a new retaining ring.
1. Make sure the index marks made during disassembly are aligned.
2. Install the synchronizer assembly with the deeper center flange of the synchronizer hub facing toward the rear of the output shaft.
  - It may be necessary to press the hub into position on the shaft.
    
    Fig 1: Assembling First/Second Synchronizer Assembly
    Courtesy of FORD MOTOR CO.
    
    Fig 2: Installing First/Second Synchronizer Assembly On Output Shaft
    Courtesy of FORD MOTOR CO.
Install the first gear synchronizer blocking ring.
- Align the blocking ring tabs with the synchronizer assembly.
  
  Fig 3: Installing First Gear Synchronizer Blocking Ring
  Courtesy of FORD MOTOR CO.
Install the outer first gear synchronizer cone.

Fig 4: Installing Outer First Gear Synchronizer Cone
Courtesy of FORD MOTOR CO.
Install the inner first gear synchronizer cone. Rotate the inner cone till it is seated.

Fig 5: Installing Inner First Gear Synchronizer Cone
Courtesy of FORD MOTOR CO.
Install the first gear needle bearing.
- Apply petroleum jelly to the bearing.
  
  Fig 6: Installing First Gear Needle Bearing
  Courtesy of FORD MOTOR CO.
Install first gear.
- Rotate the gear to align the gear slots with the inner cone tabs.
  
  Fig 7: Installing First Gear
  Courtesy of FORD MOTOR CO.
Install the reverse synchronizer cone.

Fig 8: Installing Reverse Synchronizer Cone
Courtesy of FORD MOTOR CO.
Install the reverse gear blocking ring.

Fig 9: Installing Reverse Gear Blocking Ring
Courtesy of FORD MOTOR CO.
Using the special tools, install the reverse gear bearing spacer.

Fig 10: Installing Reverse Gear Bearing Spacer

G03378675

Courtesy of FORD MOTOR CO.

Install reverse gear needle bearing.
- Apply petroleum jelly to the bearing.
  
  Fig 11: Installing Reverse Gear Needle Bearing
  Courtesy of FORD MOTOR CO.
Install the reverse gear synchronizer assembly.

Fig 12: Installing Reverse Gear Synchronizer Assembly
Courtesy of FORD MOTOR CO.
Install reverse gear.
- Rotate the gear to align the gear slots with the inner cone tabs.
- Make sure the clutching teeth on the gear snap inside the sliding sleeve and the sliding sleeve is against the gear.
  
  Fig 13: Installing Reverse Gear
  Courtesy of FORD MOTOR CO.
Install the check ball.
- Use petroleum jelly to hold the check ball in place.
  
  Fig 14: Installing Check Ball
  Courtesy of FORD MOTOR CO.
Install the thrust washer. Be sure to align the slot in the washer with the check ball.

Fig 15: Installing Thrust Washer
Courtesy of FORD MOTOR CO.
Install a new rear output shaft bearing, then fifth gear. Using the special tool, press both the bearing and gear into place.

Fig 16: Installing Rear Output Shaft Bearing & Fifth Gear

G03378681

Courtesy of FORD MOTOR CO.

Reposition the output shaft with the input end facing upward.
Install the second gear synchronizer blocking ring. Rotate the blocking ring until seated.

Fig 17: Installing Second Gear Synchronizer Blocking Ring
Courtesy of FORD MOTOR CO.
Install the second gear synchronizer outer cone and the second gear synchronizer inner cone.

Fig 18: Installing Second Gear Synchronizer Outer & Inner Cones (1 Of 2)
Courtesy of FORD MOTOR CO.

Fig 19: Installing Second Gear Synchronizer Outer & Inner Cones (2 Of 2)
Courtesy of FORD MOTOR CO.
Install the second gear bearing.
- Apply petroleum jelly to the bearing.
  
  Fig 20: Installing Second Gear Bearing
  Courtesy of FORD MOTOR CO.
Install second gear.
- Rotate the gear to align the gear slots with the inner cone tabs.
  
  Fig 21: Installing Second Gear
  Courtesy of FORD MOTOR CO.
Install the check ball.
- Use petroleum jelly to hold the check ball in place.
  
  Fig 22: Installing Check Ball
  Courtesy of FORD MOTOR CO.
Install the thrust washer. Be sure to align the slot in the washer with the check ball.

Fig 23: Installing Thrust Washer
Courtesy of FORD MOTOR CO.
Press the bearing spacer onto the output shaft.

Fig 24: Installing Bearing Spacer

G03378689

Courtesy of FORD MOTOR CO.

Install the third gear bearing.
- Apply petroleum jelly to the bearing.
  
  Fig 25: Installing Third Gear Bearing
  Courtesy of FORD MOTOR CO.
Install third gear.

Fig 26: Installing Third Gear
Courtesy of FORD MOTOR CO.
Install the third gear synchronizer blocking ring.

Fig 27: Installing Third Gear Synchronizer Blocking Ring
Courtesy of FORD MOTOR CO.
Install the third/fourth gear synchronizer body.
- Install the synchronizer body with the raised center facing downward.
- Rotate the blocking ring until seated.
  
  Fig 28: Installing Third/Fourth Gear Synchronizer Body
  Courtesy of FORD MOTOR CO.
Install a new retaining ring.

Fig 29: Installing New Retaining Ring
Courtesy of FORD MOTOR CO.