Output Shaft: Disassembly

Remove the retaining ring above fifth gear.

Fig 1: Removing Retaining Ring Above Fifth Gear
Courtesy of FORD MOTOR CO.

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

CAUTION: Support the output shaft while using the press to prevent damage to the shaft or gears.

Using the special tool, press fifth gear, the spacer, the output shaft bearing and reverse gear from the output shaft.
- Discard the output shaft bearing.
  
  Fig 2: Removing Fifth Gear From Output Shaft
  Courtesy of FORD MOTOR CO.
Remove reverse gear needle bearing.
- Inspect the needle bearing for wear or damage. Install a new needle bearing as necessary.
  
  Fig 3: Removing Reverse Gear Needle Bearing
  Courtesy of FORD MOTOR CO.
Remove the check ball and the blocking ring.
- Inspect the blocking ring for wear or damage. Install new blocking rings as necessary.
  
  Fig 4: Removing Check Ball And Blocking Ring
  Courtesy of FORD MOTOR CO.

NOTE: Install the special tool with the flat side facing first gear.

Fig 5: Removing Bearing Spacer, Reverse Gear Synchronizer Cone & First Gear

Courtesy of FORD MOTOR CO.

Using the special tools, press the bearing spacer, the reverse gear synchronizer cone and first gear from the output shaft.
Remove the first gear needle bearing.
- Inspect the needle bearing for wear or damage. Install a new needle bearing as necessary.
  
  Fig 6: Removing First Gear Needle Bearing
  Courtesy of FORD MOTOR CO.
Remove the first gear synchronizer inner cone, the first gear synchronizer outer cone and the first gear synchronizer blocking ring.
- Inspect all components for wear or damage. Install new components as necessary.
  
  Fig 7: Removing First Gear Synchronizer Components
  Courtesy of FORD MOTOR CO.

NOTE: Reposition the output shaft on the press with the input shaft end facing upward.

Fig 8: Removing Retaining Ring

Courtesy of FORD MOTOR CO.

Remove and discard the retaining ring.
Remove the third/fourth synchronizer hub.

Fig 9: Removing Third/Fourth Synchronizer Hub
Courtesy of FORD MOTOR CO.
Remove the third/fourth blocking ring.

Fig 10: Removing Third/Fourth Blocking Ring
Courtesy of FORD MOTOR CO.
Remove the third gear.
- Inspect the gear for wear or damage. Install a new gear as necessary.
  
  Fig 11: Removing Third Gear
  Courtesy of FORD MOTOR CO.
Remove the third gear needle bearing.
- Inspect the needle bearing for wear or damage. Install a new needle bearing as necessary.
  
  Fig 12: Removing Third Gear Needle Bearing
  Courtesy of FORD MOTOR CO.

NOTE: Install the special tool behind second gear with the flat side of the tool facing second gear.

Using the special tool, remove the spacer, second gear thrust washer and second gear.
- Inspect the gear for wear or damage. Install a new gear as necessary.
  
  Fig 13: Removing Spacer, Second Gear Thrust Washer & Second Gear
  Courtesy of FORD MOTOR CO.
Remove the check ball and second gear needle bearing.
- Inspect the needle bearing for wear or damage. Install a new needle bearing as necessary.
  
  Fig 14: Removing Check Ball & Second Gear Needle Bearing
  Courtesy of FORD MOTOR CO.
Remove the second gear synchronizer inner cone, second gear synchronizer outer cone and the second gear synchronizer blocking ring.
- Inspect all components for wear or damage. Install new components as necessary.
  
  Fig 15: Removing Second Gear Synchronizer Components
  Courtesy of FORD MOTOR CO.
Remove the snap ring, then using the special tool, press off the first/second gear synchronizer.

Fig 16: Removing First/Second Gear Synchronizer
Courtesy of FORD MOTOR CO.